Danieli, one of the world’s leading technology providers for the metals industry, has launched two highly innovative projects developed for Emsteel, a green steel production leader in the Gulf region. The initiatives—focused on the electrification of direct reduction processes and the implementation of advanced thermo-mechanical control for high-strength beams—mark a further step in the global sustainable transformation of the steel sector.
The first project involves installing an electric module to preheat the natural gas used in the Energiron© direct reduction plant for iron ore, a technology jointly developed by Tenova and Danieli. This innovation reduces direct combustion, significantly lowering emissions and enhancing overall process efficiency.
Emsteel currently operates three modules equipped with CO₂ separation and capture systems and utilizes hot charging into electric arc furnaces (EAF), keeping the pre-reduced material at around 600°C. Electrifying the gas heating process represents a crucial evolution toward near-zero-emission green steel production.
The second project concerns the modernization of Emsteel’s heavy-section mill in Abu Dhabi with the implementation of Danieli’s Thermo-Mechanical Control Process (TMCP). This technology will enable the production of ultra-large, high-strength, yet lightweight steel beams, compliant with the highest international standards of quality and safety.
Thanks to an innovative controlled cooling process, Danieli will make it possible to use steels that are easier to process yet highly resistant, improving weldability and reducing water consumption in production by up to 30%, as confirmed by testing at the Danieli Research Center.
The system will be fully integrated with process control provided by Danieli Automation and installed by Danieli Construction, ensuring operational efficiency and automated plant management.
These two new projects highlight Danieli’s commitment to advancing global steelmaking towards new levels of sustainability, efficiency, and innovation—accelerating decarbonization while enabling the construction of safer, lighter, and higher-performing infrastructure. Through these efforts, Danieli strengthens its position as a strategic partner for the most advanced steelmakers, supporting their transition to increasingly sustainable, efficient, and competitive production models.
