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Liberty Steel to build EAF at Australian Whyalla plant

  • : Metals
  • 23/04/05

UK-owned producer Liberty Steel will build an electric arc furnace (EAF) at its Whyalla plant in South Australia, to phase out coal-based steelmaking while lifting steelmaking capacity.

Liberty has inked a deal for a new low-carbon EAF with Italian equipment manufacturer Danieli, lifting the Whyalla plant's steelmaking capacity from 1mn t/yr to over 1.5mn t/yr. Engineering work has already started and construction is expected to be completed in 2025, said Liberty Steel on 4 April. The new EAF will replace the plant's existing coke ovens and blast furnace.

The furnace will initially be fed domestic steel scrap and other iron-bearing materials to deliver an expected 90pc reduction in direct CO2 emissions compared with traditional blast furnace production.

Danieli's patented Q-One technology allows for a direct feed from green power sources, aligning the plant with plans for future renewable energy development in the Spencer Gulf region on Australia's southern coast.

The steelmaker has announced it will apply for an A$50mn ($33.6mn) state government grant to partially fund the installation of the EAF, reported to require an investment of between A$400-500mn.

The company has also engaged global equipment suppliers to install a 1.8mn t/yr direct reduction plant in Whyalla that can process local magnetite ore to produce low carbon iron. The plant will initially use a mix of natural gas and green hydrogen as the reducing agent, before fully transitioning to green hydrogen once that is available at scale. The low carbon iron can be fed into the EAF with scrap to produce high-quality steel grades.

UK-based GFG Alliance, Liberty Steel's parent company, also plans to produce up to 7.5mn t/yr of green iron pellet at the Whyalla plant.

The new EAF at the Whyalla plant follows a commitment by Liberty to shift to green steelmaking, after the British company acquired the Whyalla works that is located 230km north of Adelaide in 2017. Construction for the new furnace was originally scheduled to begin in 2021.

Liberty Steel also ordered two EAFs for its Ostrava plant in the Czech Republic last year.


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