Tenova’s Green City Mill Flex: Shaping the Future of Sustainable Steel Production
On February 21, 2025, Vinton Steel LLC, a subsidiary of Kyoei Steel, awarded Tenova a pivotal contract for the supply of advanced technologies to their facility in El Paso, Texas. The centerpiece of this groundbreaking project is Tenova’s Green City Mill Flex, a cutting-edge platform designed to reshape steel production in North America. This technological evolution aims to raise production capacity to 400,000 metric tons annually while simultaneously reducing emissions, energy consumption, and operational costs.
A Milestone for Sustainable Steelmaking:
This significant partnership marks an important chapter in Kyoei Steel’s North American expansion strategy. Tenova’s Green City Mill Flex will play a central role in helping Vinton Steel achieve its sustainability goals. The project is designed not only to meet the growing demand for long steel products but also to demonstrate a commitment to environmental responsibility in the metals industry.
During a ceremony held on February 3, 2025, at Kyoei Steel’s headquarters in Osaka, Japan, the two companies celebrated the signing of the contract, with construction slated to begin in summer 2025. The plant is set to commence operations by Q1 2027, solidifying Tenova’s role as a leading provider of green steelmaking solutions.
Innovative Green Steel Technology:
At the core of the Green City Mill Flex is a unique set of technologies that focus on product flexibility, energy efficiency, and reducing the carbon footprint of steel production. Central to this setup is the Consteel® Electric Arc Furnace technology, which is already in its third generation. This EAF technology enables continuous preheating of steel scrap, optimizing the process to reduce energy consumption and emissions. This eco-friendly design is integrated with continuous casting and rolling capabilities through collaboration with Pomini Long Rolling Mills.
By sourcing locally available steel scrap, the Green City Mill Flex adheres to circular economy principles, encouraging recycling and reducing the need for new raw materials. This further minimizes the environmental impact of steel production, making it one of the most sustainable approaches to steelmaking in urban environments.
The Project's Cutting-Edge Technologies:
Under the agreement, Tenova will provide a full suite of state-of-the-art equipment and systems for the Vinton Steel plant. Some of the key components of the Green City Mill Flex include:
• A 45-ton Consteel® EAF with continuous scrap preheating for enhanced energy efficiency.
• An in-line Ladle Metallurgy Furnace to ensure precise steel refining.
• A multi-strand Continuous Casting Machine to enhance casting flexibility.
• An automated Material Handling System for smooth and efficient operations.
• An advanced Fume Treatment Plant, including a quenching tower and pulse-jet baghouse, designed to mitigate emissions.
• A zero-water-consumption Water Treatment Plant, highlighting the plant’s focus on sustainability.
• A new Electrical Distribution System to optimize energy usage.
Techint Engineering & Construction’s Role:
The project will be managed through an EPCM contract by Techint Engineering & Construction, a subsidiary of Techint Group, Tenova’s parent company. Techint E&C’s extensive experience in industrial infrastructure will ensure the construction process adheres to the highest standards of quality, safety, and efficiency, with completion scheduled for 2027.
A Leap Forward for Green Steel in the U.S.:
This project sets a new benchmark for regional steel production plants in the U.S., especially in terms of sustainability and flexibility. With Tenova's Green City Mill Flex, long-steel producers can modernize their operations to meet the growing demand for low-carbon steel while maintaining high efficiency and reducing costs. This partnership underscores the increasing importance of green technologies in the U.S. metals industry, aligning with global trends toward environmentally friendly manufacturing.
Key Takeaways:
• Green City Mill Flex technology by Tenova is set to enhance Vinton Steel's capacity to 400,000 metric tons per year.
• The project aims to reduce emissions, energy consumption, and operational costs through cutting-edge sustainable steelmaking technologies.
• Central to the project is the Consteel® Electric Arc Furnace (EAF) technology, which includes continuous scrap preheating for greater energy efficiency.
• The plant will also feature continuous casting and rolling capabilities in partnership with Pomini Long Rolling Mills.
• The project emphasizes local steel scrap recycling to support a circular economy, reducing environmental impact.
• Tenova will provide a complete suite of technologies, including an advanced Fume Treatment Plant and zero-water-consumption Water Treatment Plant.
• The construction of the plant is scheduled to begin in summer 2025, with startup expected in Q1 2027.
• Techint Engineering & Construction will oversee the project to ensure high-quality, safe, and efficient construction practices.
• The project highlights a major investment in green steelmaking and supports Kyoei Steel’s expansion in North America.
