Algoma Steel achieves first heat in transformation to electric arc steelmaking

Algoma Steel, a leading Canadian producer of hot and cold rolled steel sheet and plate products, has successfully achieved first steel production at Unit One of its new state-of-the-art Electric Arc Furnace (EAF) facility in Sault Ste. Marie, Ontario.

This is the first heat from one of two new Danieli Digimelter EAFs, which will produce high-quality liquid steel using recycled scrap metal, with the flexibility to incorporate a wide range of other iron inputs. Once completed, Algoma’s transformation will represent the first full transition from integrated to electric arc steelmaking to enter operation anywhere in the world.

Digimelter #1 is part of Algoma’s new green steel shop supplied by Danieli. The facility is designed with an annual production capacity of 3.7 million tons of liquid steel, supported by two 250-ton EAFs. Both EAF’s will be powered by Q-One digital power systems, each delivering more than 150 MVA. The melt shop will also leverage two existing ladle furnaces, along with a new Danieli twin-tank vacuum degasser, enabling the production of exceptionally clean steel.

By adopting advanced Danieli technologies, Algoma is expected to reduce carbon emissions by approximately 70%. When powered with Ontario’s clean electrical grid the company is well-positioned to become a leading North American green steel producer.

The Danieli-patented Q-One power feeder enables continuous frequency variation throughout the melting phases, enhancing energy efficiency and reducing electrode consumption. In addition to minimizing impact on the power grid, Q-One is the only technology that enables direct use of renewable energy resources for electric steelmaking. The process is further optimized through the Danieli Q-Melt automatic process control suite, which ensures consistent energy efficiency.

The twin-tank vacuum degasser, equipped with oxygen-blowing, will support the production of advanced steel grades and further improve product quality of coil and plate applications.

The melt shop’s design prioritizes environmental performance, with engineered enclosures surrounding the two furnaces to reduce noise and emissions. Two new off-gas fume treatment plants, including baghouses and a dedicated recirculating water-treatment plant, will provide industry leading filtration, emission control, and water conservation.

Algoma’s transition also includes an automated scrapyard, featuring automated cranes, scrap visual recognition, and automated scrap sorting and charging - enhancing both safety and operational efficiency.