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Steelworks & Foundries Handling Solutions

About the Steelworks & Foundries Industry

The steelworks and foundries sector is a cornerstone of modern manufacturing, transforming raw materials into essential components for construction, transportation, and countless other industries. Steel production primarily relies on recycled scrap metals, supplemented by iron ore (Fe) and carbon (C) sources to produce alloys with specific mechanical properties. Foundries play a complementary role by creating cast components, heating metals to molten states exceeding 1,400°C (for steel) and pouring them into molds to achieve intricate geometries.

Globally, the steel industry remains a massive economic force. In 2023, the Iron & Steel Manufacturing market reached a valuation of $17.9 billion CAD in Canada and $1.6 trillion USD in the United States. The reliance on recycled ferrous materials underscores the industry’s commitment to sustainability, reducing reliance on mining virgin ores and lowering carbon footprints through the circular use of metals.

Sustainable Developments and Challenges in the Industry

Challenges in Steel Manufacturing and Foundries

The industry faces several persistent challenges that demand innovative solutions:

  1. Raw Material Volatility: Supply chain disruptions and rising costs of iron (Fe), carbon-based materials like coal, and specialized alloying elements (e.g., chromium [Cr], manganese [Mn], and nickel [Ni]) strain production budgets and profit margins.
  2. Energy-Intensive Processes: Steelmaking in basic oxygen furnaces (BOFs) and electric arc furnaces (EAFs) consumes vast amounts of energy, contributing significantly to greenhouse gas emissions, particularly CO₂.
  3. Worker Safety: High-temperature operations, chemical hazards from flux materials (e.g., calcium oxide [CaO]), and toxic by-products like sulfur dioxide (SO₂) and nitrogen oxides (NOₓ) pose risks to health and safety.
  4. Labor Shortages: Aging workforces and skill gaps limit the industry’s ability to sustain growth while meeting increasing global demand.

Innovations Driving Sustainability

To overcome these challenges, the steelworks and foundries industry has embraced transformative technologies and practices focused on safety, efficiency, and environmental stewardship.

  1. Recycling and Circular Economy:
  • Steel is infinitely recyclable without degradation, making it a cornerstone of a circular economy. By recycling ferrous materials, the industry reduces the need for mining hematite (Fe₂O₃) and magnetite (Fe₃O₄) ores, conserving natural resources and decreasing energy use by up to 75% compared to primary steelmaking.
  • Slag, a by-product rich in calcium silicates (CaSiO₃), is increasingly repurposed in cement production, reducing waste and supporting sustainable construction.

  1. Non-Destructive Testing (NDT) and Monitoring: Advanced inspection methods, such as ultrasonic testing and radiographic analysis, are used to detect microfractures, corrosion, and structural weaknesses in machinery and components. Remote monitoring systems equipped with IoT sensors continuously track conditions like temperature, pressure, and material stresses, enabling predictive maintenance and minimizing downtime.

  2. Digital Transformation:
  • Automation and robotics now handle hazardous tasks such as molten metal pouring, reducing worker exposure to extreme heat and harmful fumes.
  • Data analytics and artificial intelligence optimize processes by analyzing real-time furnace conditions and chemical compositions, improving energy efficiency and reducing raw material waste.

  1. Energy Efficiency and Green Technologies:
  • Electric Arc Furnaces (EAFs), which use primarily recycled scrap, are more energy-efficient than traditional BOFs, producing less CO₂ per ton of steel.
  • Hydrogen (H₂)-based steelmaking is emerging as a revolutionary technology, replacing carbon-intensive coke with H₂ as a reducing agent for iron ore. This process emits water (H₂O) instead of CO₂, marking a significant leap toward decarbonization.

  1. Sustainability Certifications and Environmental Compliance:  Many companies are pursuing certifications such as ISO 14001, which focuses on environmental management systems. Efforts to reduce emissions of particulate matter (PM), volatile organic compounds (VOCs), and hazardous air pollutants (HAPs) are helping facilities meet stringent environmental regulations.

Future Outlook: A Balance Between Growth and Responsibility

As global demand for steel continues to rise—driven by infrastructure expansion, renewable energy projects, and electric vehicle (EV) production—the steelworks and foundries industry is under pressure to balance growth with sustainability. The integration of cleaner technologies, resource-efficient practices, and circular material flows ensures that the industry remains both economically viable and environmentally responsible.

Through innovations such as hydrogen-based reduction, slag valorization, and advanced monitoring systems, the steelworks and foundries sector is transforming itself into a leader in sustainable manufacturing. By addressing the challenges of today with the technologies of tomorrow, the industry plays a pivotal role in building a greener, more resilient global economy.

WTW Americas Industry Experience

WTW Americas is a global leader in material handling and process optimization, with extensive experience in the steelworks and foundries industry. Our robust equipment and innovative solutions are trusted by industry leaders across the globe. With installations in facilities handling Iron Ores, Coal, Coke, Slags, plus other raw Ores and byproducts of Steel manufacturing, our systems are designed to optimize production efficiency, ensure consistent material flow, and address the unique challenges of high-temperature and abrasive processes. WTW Americas has worldwide installations in the Steelworks and Foundries Industry. Our references include Steelworks Design, U.S Steel, Ternium, and many more.

Our clients include some of the most recognizable names in the steelworks and foundries industry, and the majority of our business comes from repeat customers who value our reliable equipment and commitment to excellence. From raw material handling, waste material storage, and reclaiming materials, WTW Americas provides tailored solutions that integrate seamlessly into every stage of the production process.

Customized Solutions for the Steelworks and Foundries Industry

Material Reception and Storage Solutions

At the start of the production process, the efficient handling of raw materials such as iron ore (Fe₂O₃), coke (a carbon-rich material), coal, and other raw ores is critical. WTW Americas’ Truck Discharge Machine (TDM) offers a high-capacity solution for 3 unloading materials from trucks, railcars, barges, or front-end loaders. The TDM is engineered to handle bulk materials at rates of up to 1,200 t/h while minimizing civil work requirements, reducing installation costs, and accelerating the integration of the equipment into existing operations.

For facilities requiring intermediate storage, our Silo Discharge Machine (SDM) is an ideal choice. Designed to handle cohesive, hot, and abrasive materials such as slag, sinter, and pellets, the SDM ensures mass flow and prevents issues like ratholing or bridging. Its unique rotating discharge arm activates the entire silo floor, maintaining material flowability and preventing solidification over time.

The Bunker Discharge Machine (BDM) complements these systems by efficiently reclaiming materials from stockpiles, silos, and hoppers, with reclaim rates ranging from 10 to 2,500 t/h. Frequently used for transporting raw iron ore, ferroalloys, and additives, the BDM integrates seamlessly into conveying systems for continuous material flow.

Conveying and Transporting Throughout the Process

High-temperature, sticky, and abrasive materials, such as slag, dust-laden coke, and scale, present significant challenges for traditional conveying systems. WTW Americas addresses these challenges with our TKF Chain Conveyors, engineered to transport materials with high precision and minimal loss. Chain Conveyors have been used to transport material, unload railcars, silos, hoppers, and to clean out cooling water baths.

  • Explosion-Proof and Dust-Tight Design: To mitigate fire, explosion, and dust exposure risks, the TKF Chain Conveyor is fully enclosed, ensuring safety and compliance with industry regulations.
  • Flexible Configurations: These conveyors can operate horizontally, vertically, or on an incline, and are capable of handling loads from 0 to 1,000 t/h.
  • Durability: Manufactured using high-quality alloy steels and subjected to rigorous testing, our chain systems are designed to withstand extreme temperatures (up to 750°C) and abrasive environments, ensuring long-lasting performance.

Key Benefits of WTW Americas’ Solutions for Steelworks and Foundries

  1. Increased Process Reliability: Our systems ensure consistent material flow, reducing operational interruptions and downtime.
  2. Energy Efficiency: WTW equipment is designed to optimize resource use, contributing to a more sustainable and cost-effective production process.
  3. Worker Safety: Automated systems and dust-tight designs minimize worker exposure to hazardous environments.
  4. Customizability: Each solution is tailored to meet the specific demands of our clients, from handling hot slag to storing and transporting steel products.

Trusted by the Industry

WTW Americas’ long-standing reputation in the steelworks and foundries sector is built on decades of successful installations and satisfied customers. Our repeat clientele is a testament to the reliability and effectiveness of our solutions. Whether addressing challenges in raw material reception, intermediate storage, or finished product handling, WTW Americas delivers equipment that enhances operational efficiency and supports the demanding requirements of steelworks and foundries around the world.

For more information about our industry-specific equipment, visit our equipment page.

Learn More

To learn more about WTW Americas equipment and experience in the Steelworks & Foundries Industry email info@wtwamericas.com or call +1705-749-3544.

Contact Us

Email
info@wtwamericas.com

Phone
705-749-3544

Address
159 King St. Suite 208
Peterborough, ON, Canada
K9J 7H7

WTW Americas specializes in handling sticky, wet, hot (up to 750°C), abrasive and non-free-flowing bulk materials.

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