Over 1,000 people, from Tata Steel as well as contractors, are involved in Port Talbot’s transition to low emission steelmaking. Their new headquarters, a massive set of modular buildings fitted out by local contractors, Wernick, have just been installed over the summer. Now they are hard at work on the £1.25 billion construction of the new Electric Arc Furnace (EAF) and mills development programme, on target for its start-up phase at the end of 2027.

There are four main construction projects, which Stephen Horn, PMO Manager for Strategic Capex, outlines:
‘As well as the electric arc furnace, we are building a brand new pickle line, plus there are life-extension projects for the hot strip mill and both casters. And we are keeping assets running so we can continue to supply products as we work to bring the new ones on stream – which is no small undertaking.’

The first projects due to be completed in December 2027 are the EAF, the new pickle line, and caster 1. Caster 2 will follow shortly after along with the hot strip mill.

The new, state-of-the-art pickle line will eliminate oxide scale formed during the steel rolling process to create a clean surface for further processing. It will manufacture both pickled and oiled and cold rolled products and its enhanced capability will mean it can process thicker, wider and higher-strength material that we know our customers need. Geared to high quality production, the new line will feature a powerful tension leveller to improve strip flatness, and an industry-leading laser welder to ensure reliable coil joining, including for advanced high strength steel grades. On-site acid regeneration means the new line will be less reliant on external markets, ensuring reliable operations and deliveries. The acid recovery, coupled with waste-stream collection and the latest exhaust and scrubber systems, will put the plant at world-class benchmark sustainability levels.  

‘It’s an example of how we are future-proofing for greener and smarter operations,’ says Stephen Horn.

Basic engineering at the hot strip mill and pickle line with global steel processing supplier, Clecim and technology leader ABB has now been completed, allowing the project to transition into the detailed design phase.
Meanwhile, before a single brick of the new EAF steelmaking technology can be laid, there’s a massive amount of preparation work to be done. One of the first tasks has been to strip out and repurpose the charging, converter and teeming bays of the former Basic Oxygen Steelmaking (BOS) plant. Around 180 workers from 35 contracting companies joined forces with Tata Steel staff to remove a 130-tonne crane, two ladle repair stands, internal scrap weighbridges, bogeys, and the enormous RH  Degasser unit. Meanwhile enabling works has seen the removal of no less than 175,000 cubic metres of stone, clay and concrete. Most of this material is being crushed and repurposed for use on site, for example for infilling some of the lagoon to create an approach road to the new electric arc furnace.

The investment programme has put a great deal of focus on Port Talbot, but we never forget that the work we are doing here will make a transformative difference to customers, bringing low emission steel with high recycled content across the product range through our operations in Corby, Hartlepool, Trostre, Llanwern, Shotton and Wednesfield.