Marcegaglia Stainless Sheffield, a key player in the global stainless steel industry, has embarked on an ambitious modernization project in collaboration with Primetals Technologies, one of the world’s leading suppliers of technology and automation systems for the steel industry. The agreement, announced in late November 2024, focuses on optimizing and upgrading the Sheffield minimill's production processes with the goal of increasing the plant’s annual production capacity from 250,000 to 500,000 metric tons of stainless steel. This significant productivity boost will position the Sheffield plant to better meet rising global demand for high-quality stainless steel products.
The centerpiece of this partnership is the comprehensive upgrade of the Sheffield minimill’s process optimization systems. Marcegaglia Stainless chose Primetals Technologies based on its deep technical expertise and experience in large-scale steel production upgrades. The modernization plan involves a series of carefully planned steps over the short, medium, and long term. The project’s first phase will focus on immediate upgrades, including the installation of advanced automation systems designed to enhance process control and optimize steelmaking efficiency.
A key element in Marcegaglia’s decision to partner with Primetals Technologies was the results of a Through-Process Optimization study conducted by Primetals Technologies earlier this year. The TPO study provided a detailed analysis of the plant’s current production processes, identifying inefficiencies, bottlenecks, and areas where improvements could be made. Based on the insights from this study, a roadmap for upgrading and optimizing the plant’s various operations was developed, ensuring that the improvements will be tailored to the specific needs of the Sheffield minimill.
The first major upgrade, to be implemented in the early stages of the project, is the installation of Melt Expert, an advanced, fully automated electrode control system for the electric arc and ladle furnaces. This system will help optimize the energy consumption of the furnaces and ensure more consistent and efficient steel production. Mid-term plans include the integration of additional process optimization software for the electric arc furnace, argon-oxygen decarburization, and ladle furnace. These upgrades, which were previously lacking from the mill’s automation systems, will provide real-time process monitoring and dynamic control, enabling further improvements in product quality and production efficiency.
The long-term strategy for the Sheffield plant includes the replacement of the electric arc furnace to accommodate the increased production capacity. This will involve implementing new technologies to increase the furnace's productivity while maintaining or even improving its energy efficiency and environmental performance. These upgrades are essential for Marcegaglia to meet its production targets and ensure that the plant can meet the growing demand for high-quality stainless steel products in the global market.
The partnership between Marcegaglia and Primetals Technologies goes beyond just the installation of advanced systems and technology. According to Tom Eades, Engineering Manager at Marcegaglia, the collaboration is intended to foster a long-term relationship focused on continuous improvement and ongoing system updates. The companies have emphasized the importance of knowledge transfer and training, ensuring that Marcegaglia’s workforce will have the skills and expertise necessary to operate the upgraded systems efficiently. Primetals Technologies will provide digitalized knowledge, recommended actions, and training sessions to the plant’s operators, helping them integrate best practices into their daily operations.
One of the most exciting aspects of the project is the integration of intelligent sensors and process optimization solutions. These systems are designed to monitor specific process steps, such as scrap loading and furnace operation, in real-time. For example, the Scrap Basket Profile Monitor will track the scrap input process and identify any deviations from standard operating conditions, alerting operators to potential issues before they affect the overall production process. Similarly, the Ladle Tracker will optimize the ladle management process, suggesting the most appropriate ladle for each batch of steel to avoid quality losses due to residues left from previous batches.
In addition to these advanced process optimization systems, the project will include the implementation of tools that help reduce production costs. The Scrap Yard Supervisor, for instance, will calculate cost-optimized scrap recipes, taking into account the available scrap quality and composition. This solution helps ensure that the most efficient and cost-effective scrap is used in each production batch, reducing waste and improving overall cost-efficiency.
Marcegaglia Stainless Sheffield is known globally for its high-quality long stainless steel products, which include a wide range of grades, shapes, and sizes used in various industries. With a strong commitment to sustainability, Marcegaglia produces stainless steel with over 90% recycled content, making it one of the most environmentally conscious steelmakers in Europe. The company has long been dedicated to improving the sustainability of its production processes, and this new collaboration with Primetals Technologies is a key step in ensuring that the Sheffield plant continues to meet the highest environmental and quality standards.
The Sheffield plant’s upgraded production capabilities will enable Marcegaglia to better meet the needs of customers in sectors such as automotive, construction, and electrical industries. The high-quality stainless steel produced at Sheffield is used in a variety of applications, from automotive exhaust systems to high-performance electrical components, and the company’s ability to produce these materials more efficiently will enhance its competitive edge in global markets.
