Swiss Steel commissions the world’s first electric forging furnace
The Swiss Steel Group has converted a forging furnace at its Finkl Steel-Sorel Québec plant from fossil fuels to electric power. Heating the furnace with renewable electricity reduces the carbon footprint and, according to the company, brings further benefits to the production process and to the people working at the plant.
“The first electric forging furnace in our Group is a prime example of ‘Forging the future’. It paves the way for the further electrification of larger furnaces, enabling us to continuously and sustainably reduce our carbon footprint in line with our decarbonisation roadmap,” says Olivier Lebrun, CTO of the Swiss Steel Group. “The conversion of the furnace technology is a groundbreaking engineering achievement and sets the standard for the Swiss Steel Group and the entire steel industry.” The electrification of the forging furnace at the Finkl Steel-Sorel plant in the Canadian province of Québec alone could save up to 3,000 tonnes of greenhouse gas emissions per year.
According to the company, the conversion of the Swiss Steel Group’s first forging furnace to electric heating was also the first installation of its kind worldwide. In addition to reducing CO₂ emissions, the switch from natural gas to electricity is also associated with increased output and savings in energy consumption, as the company reports. Modelling has shown, for example, a significant reduction in heat loss and thus greater energy efficiency. A more stable process, improved plant availability and reduced maintenance requirements are also anticipated. A further advantage stems from the reduction in steel oxidation within the furnace: Electric heating produces less scale and thus less material loss.
The switch to electric furnace technology also has a positive impact on the health and safety of employees: electric heating furnaces are safer to operate and air quality in the plant is better, whilst dust levels are lower. Furthermore, the electric forging furnace is safer to operate and easier to maintain.
Same performance, highest quality
According to Swiss Steel, all these advantages are achieved whilst maintaining the highest quality standards (temperature homogeneity, etc.) and delivering the same heating capacity as in a gas-fired furnace. This had already been demonstrated by simulations and feasibility studies carried out in the run-up to the project, which were developed in collaboration with scientists at the Research Chair at ETS University (École de technologie supérieure) in Montreal. They specialise in applied teaching and research in engineering, as well as in the transfer of advanced technologies to businesses.
As part of the conversion, all burners and natural gas-related components were removed and 36 tubular heating elements were installed, capable of withstanding temperatures of up to 1,600 °C. In addition, new electrical control systems were installed, supplying the furnace with 1.4 MW. Another innovation is the use of a new refractory material that has the same insulating properties as ceramic wool but does not emit any pollutants.
’s electrified process chain The plant is powered entirely by hydropower – one of the lowest-emission forms of energy generation – which further improves the site’s environmental footprint. The new electric forging furnace at Finkl Steel-Sorel Québec can heat ingots weighing up to 40 tonnes before they are forged on a press that has also recently been upgraded and then undergo further processing. The entire process chain, from the electric arc furnace to the heat treatment facilities, can now be powered by electricity, enabling the plant to offer customers the highest-quality, low-emission steel products.
The plant in St-Joseph-de-Sorel specialises in tool steels and high-quality structural steels. With its 2,000-metric-tonne open-die press and the new 6,700-metric-tonne press, the plant can forge and heat-treat workpieces of a wide variety of shapes and sizes to customer specifications.
Source: Swiss Steel