After testing two specialized metallurgy analyzers, SSAB selected the ABB EL3020 for its unique combination of accuracy, moisture resistance, and real-time performance:
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- High-Precision Multi-Gas Measurement: The EL3020 uses Fourier-transform infrared (FTIR) spectroscopy to measure H₂, CO, H₂O, and CO₂ with ±0.1% accuracy—30x more precise than TCD analyzers. It maintains this accuracy even at H₂ concentrations up to 99.9%, critical for SSAB’s DR process.
- Moisture Immunity: Advanced optical filtering eliminates H₂O interference, providing reliable readings even at 30% relative humidity in the furnace off-gas. The analyzer’s heated sampling line (180°C) prevents condensation, ensuring consistent measurements.
- Real-Time Process Feedback: With a 500ms update rate, the EL3020 delivers instant gas composition data to SSAB’s furnace control system, enabling automatic adjustments to hydrogen flow rates and furnace temperature. This closed-loop control minimizes process variability.
- Sustainability Alignment: The EL3020’s low power consumption (15W) aligns with SSAB’s fossil-free goals. It also supports remote monitoring via ABB’s Ability™ platform, reducing on-site maintenance and carbon footprint.
Results: Higher Quality, Lower Costs, and Greener Production
Six months post-deployment, SSAB’s HYBRIT plant achieved transformative results:
- 12% Improvement in Steel Quality: Scrap rates dropped from 15% to 3% as precise gas control ensured consistent iron ore reduction. The sponge iron’s oxygen content fell from 2.3% to 1.1%, improving downstream steelmaking efficiency.
- 8% Reduction in Energy Consumption: Real-time hydrogen flow optimization cut green hydrogen usage by 8%, saving 4,800 MWh of renewable energy annually—equivalent to reducing CO₂ emissions by 1,200 tons (since HYBRIT’s hydrogen is fossil-free).
- 30% Faster Process Ramp-Up: The EL3020’s reliable data enabled SSAB to reduce furnace startup time from 48 hours to 34 hours, increasing plant capacity utilization by 12%.
- Enhanced Sustainability Reporting: Accurate gas composition data improved tracking of the plant’s carbon footprint, supporting SSAB’s goal of delivering 1.5 million tons of fossil-free steel annually by 2030.
“The EL3020 has been a game-changer for our fossil-free steel production,” Larsson said. “Its precision has unlocked consistent quality and efficiency gains that were impossible with our old analyzers. It’s a critical tool for scaling sustainable steelmaking.”
Anders Pettersson, ABB’s Global Head of Metallurgy Solutions, emphasized the EL3020’s industry impact: “Hydrogen metallurgy is the future of green steel, and it demands analyzers that can perform in extreme conditions. The EL3020’s FTIR technology delivers the accuracy and speed required to make fossil-free steel economically viable.”
SSAB plans to deploy the ABB EL3020 at its second HYBRIT plant in Oxelösund, Sweden, set to open in 2026, and aims to standardize the analyzer across all future fossil-free steel facilities.
