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What comes to your mind first when you think of steel production?
Most likely, massive industrial plants, extremely high temperatures, and heavy machinery...
Yes, that's true. But this picture is changing now.
A smarter, cleaner, and more sustainable era of production has begun.
So, what lies at the heart of this transformation?
Modern Electric Arc Furnace technology.
Today, the world must reduce carbon emissions, increase energy efficiency, and use natural resources more consciously.
At this very point, Electric Arc Furnaces (EAFs), which offer a powerful alternative to traditional blast furnace methods, take the stage.
Electric arc furnaces, which today are at the core of the industry, actually have a history spanning over 100 years.
But it all started with one person’s vision:
Sir William Siemens.
Who was this Siemens?
William Siemens, a 19th-century inventor and engineer, was among the first to realize the potential of electric energy to melt metals.
However, the real breakthrough came with another name:
French engineer Paul Héroult.
The year was 1907.
Héroult developed the first modern electric arc furnace, revolutionizing steel production. This technology quickly spread from Europe to America.
Why?
Because unlike fossil fuel-based furnaces, an electric furnace operated with electricity provided much more controlled, efficient, and flexible production.
Imagine a huge pile of scrap metal.
Rusty irons, old car parts, unused steel structures...
Can all of these be turned back into high-quality steel from scratch?
Yes, and in a way much more environmentally friendly and efficient than you might think.
This is exactly where the Electric Arc Furnace (EAF) comes in.
Today, producing steel alone is not enough.
How it is produced, how much harm it causes to nature, and how efficiently it uses resources are as important as the product itself.
That’s why classical methods are falling behind, and
production with Electric Arc Furnaces (EAF) is coming to the forefront.
Why? Here’s the answer:
Electric arc furnaces use a large proportion of scrap steel in production.
This means recycling existing resources.
Which means:
• Reduced consumption of natural resources.
• Increased energy efficiency.
• More controlled waste management.
And most importantly:
A solid step toward leaving a livable world for future generations.
Compared to blast furnaces, electric arc furnaces produce much lower carbon emissions.
How?
• They operate on electricity instead of fossil fuels.
• Domestic electricity production reduces dependency on external carbon sources.
• Scrap usage eliminates emissions caused by mining.
On average, they provide up to 75% carbon savings.
This benefits not only the environment but also companies in terms of carbon taxes and sustainability goals.
The electric arc furnace is a transformation center that reclaims the value of scrap.
Metals seen as waste come back to life here.
This process:
• Contributes to the economy,
• Reduces waste problems,
• Lowers steel production costs.
So both the environment and the industry benefit.
EAF technology is much more flexible compared to blast furnaces.
• Small or large scale production can be carried out as needed.
• The furnace can be started and stopped in a short time.
• Product diversity is more easily achieved.
These features are a great advantage in highly competitive markets.
Electric arc furnaces do not only produce steel;
they also form the sustainable backbone of modern industry.
So where do we encounter these huge, energy-rich furnaces?
This is the most common usage area.
Electric arc furnaces are especially preferred for melting scrap to produce molten steel.
• Construction steels
• Automotive steels
• Machinery and mold steels
and many other products are born in these furnaces.
And let’s not forget:
Leading companies like Hasçelik combine this technology with advanced quality control and environmentally friendly production to make a difference.
Not only ordinary steels, but also special alloys requiring high temperature and chemical resistance are produced in electric arc furnaces.
• Stainless steel
• High alloy tool steels
• Heat treatment steels
Production of these special steels requires precise temperature and chemical control.
Electric arc furnaces are experts in exactly this.
Traditional blast furnaces are designed for fixed and large-volume production.
However, many facilities want to produce steel in different sizes and qualities.
EAF systems come into play here:
• Small batches can be produced
• Flexible recipes can be applied
• Customized solutions for customer demands can be offered
The first question that comes to mind when hearing “electric arc furnace” is:
“How does this huge machine turn scrap into molten steel within seconds?”
Now let’s look behind the curtain of this miracle together.
The heart of the electric arc furnace is its graphite electrodes.
They are suspended from the top part of the furnace.
• High voltage is applied between the electrodes.
• An electric arc (visible sparks and light) forms between them.
• This arc produces an incredibly high temperature of 3,000–3,500°C.
That is, electrical energy is directly converted into heat energy.
Scrap material to be melted is loaded into the bottom part of the furnace.
Thanks to the heated electric arc, the scrap begins to melt rapidly.
• Electrodes and the arc transfer intense heat to the scrap.
• Scrap turns into molten steel.
• Temperature and duration are continuously controlled during this phase.
Molten steel is mixed with different alloying elements or purified from impurities to reach the desired chemical composition.
During melting, slag (non-metallic residues) forms and collects on the surface.
This slag is removed from the furnace with special equipment.
Molten steel is taken out of the furnace and sent to casting machines.
Here, it is solidified into semi-finished shapes such as slabs, blooms, or billets.
The electrodes, which are the heart of the electric arc furnace,
are actually one of the most critical components of this massive production process.
So, what exactly are these electrodes and why are they so important?
Electrodes are high-temperature resistant graphite rods that conduct electric current into the electric arc furnace.
Their functions:
• To conduct high-voltage electricity,
• To create the arc,
• To rapidly raise the temperature inside the furnace.
Graphite is an ideal electrode material for several reasons:
• It withstands extreme heat due to its high melting point,
• It has high electrical conductivity,
• It is resistant to thermal shocks,
• It is mechanically durable and lightweight.
Electrodes used in electric arc furnaces vary mainly in diameter and length.
• Diameters range from 300 mm to 650 mm,
• Lengths vary between 1 meter and 3 meters.
The choice depends on the furnace capacity and production requirements.
• Electrodes are suspended from the top of the furnace downwards.
• They wear down and shorten over time during use.
• They are regularly replaced or extended.
• Using high-quality electrodes directly affects the efficiency of the melting process and energy consumption.
Sustainability in steel production is no longer just a choice; it is a necessity for today and the future.
At Hasçelik Steel Plant, modern electric arc furnace technology is combined with the most innovative elements of Industry 4.0.
Smart Manufacturing with Industry 4.0 and ConSteel Technology
In Hasçelik’s steel plant, production processes are digitalized and optimized.
Thanks to advanced software like ConSteel:
• Scrap charging and energy usage are monitored in real-time,
• Operations are managed automatically and precisely,
• Error margins are minimized,
• Efficiency and quality are maximized.
Scrap Preheating: A Revolution in Energy Efficiency
Preheating the scrap used in the electric arc furnace not only reduces energy consumption but also shortens melting time and balances the temperature inside the furnace.
Thus, it ensures:
• Lower carbon emissions,
• Reduced energy costs,
• More sustainable production.
At Hasçelik, we invest not only in quality but also in the future.
With our next-generation electric arc furnace technology;
• We recycle scrap,
• Use energy more efficiently,
• Minimize carbon emissions.
Because we believe:
Our job is not just to produce strong steel, but also a clean future.
