Approval for hall expansion Refractory lining in a new dimension

New dimensions of greentec steel are being introduced into the central ladle refractory lining facility (ZAPF). In order to accommodate the larger ladles and the increase in work volume, the central ladle refractory lining facility is being expanded extensively and its capacity increased. Intensive planning has been the order of the day since January 2024, and now that authority approvals have been received, nothing can stand in the way of construction that is scheduled to begin in June 2025.

Brief explanation of the term ZAPF

ZAPF is the German abbreviation for the is the central ladle refractory lining facility. Ladles are filled with molten iron or crude steel in the steelmaking process. The ladles and vessels weighing more than 80 tons are also regularly cleaned in the ZAPF facility. Residual material such as pig iron and refractory material is broken out, and the vessels are re-lined with refractory material so that they can safely be filled with and transport the hot metal. These include the traditional torpedo ladles, hot metal charging ladles, steel casting ladles, additional hot metal charging ladles for the EAF as well as manifolds, top vessels and bottom vessels with immersion pipes for the secondary metallurgy units (Secondary Metallurgy 1-5).

Utilization of the EAF: bigger and more

The existing facility will be expanded by an additional bay in order to create enough space to make the refractory lining for the additional and somewhat larger electric arc furnace ladles. The new bay will also create space for the new Ladle Drying Stand 9 (core unit), for refractory lining pits and storing positions.

Extensive project

To ensure that the EAF route can be accompanied safely and reliably as usual, the existing ZAPF will be expanded by an indoor bay with all the necessary infrastructure measures and facilities as well as a stair tower. The entire bay will be equipped with a smoke-heat extraction system in order to meet the current legal requirements and to ensure employee safety. In order to meet operational requirements—for example, a minimum temperature of 12 °C in the center of the bay for the processing of refractory lining materials—the bay heating will be adapted and newly installed. The expansion includes the following additional measures:

  • Installation of Ladle Drying Stand 9 for the new and larger EAF vessels
  • The drying furnace for the immersion tubes is being revamped and its capacity doubled
  • Storage and material storage positions for delivery of the RH manifolds and ladle supports
  • Refractory lining pit for two ladles, including a pivoting crane (3.2 tons x 10 meters)
  • Crane runway girders will be exchanged between Axis 12 and 14 and will be installed up to Axis 15.
  • Conversion of the filter system stack to create more space for crane travel
  • Modernization of the lubrication station for excavators

The track leading east into ZAPF will be dismantled and the front area landscaped once the hall has been expanded. Steelmaking production unit structures will be transported in and out of the facility exclusively on the roadway. This is why the construction road was relocated in 2022.

Documentation for authorities Governmental approvals obtained

Following the extensive planning that began in January 2024, the government approval documents were sent to Upper Austria in October. The environmental impact assessment underwent the required governmental approval procedure in November. After receiving positive grades in the area of fire protection at the beginning of February, the official approval was issued at the end of February. Soil tests were conducted in January 2025 in view of the expected excavation volumes. The project-specific disposal strategy was submitted to the authorities at the beginning of February. The respective approval is expected sometime in the coming spring. So now nothing stands in the way of construction startup in June of 2025.

Conclusion: Ready for new ladles and vessels

Startup of the new pickling line and tandem cold-rolling mill is scheduled for middle of 2026. This ensures that the first refractory lining activities for the EAF 1 hot metal charging ladles and Secondary Metallurgy 5 (manifolds, upper vessels, lower vessels including immersion pipes) can take place in February of 2027. Successful approval of the ZAPF bay extension by the authorities is thus another important step on the way to green steel production.

Go to greentec steel

The greentec steel project of voestalpine is an ambitious step-by-step plan that makes a valuable contribution to the achievement of the climate goals. As a first step, the voestalpine Group plans to replace two blast furnaces with two electric arc furnaces (EAFs) by the year 2027. The investment volume amounts to roughly 1.5 billion euros.   

Carbon emissions can be reduced by up to 30% as early as 2029 by making this switch from the blast furnace to the EAF. This corresponds to a savings of nearly 4 million tons of CO2 per year, amounting to nearly 5% of the carbon emissions in Austria. This makes greentec steel the largest climate protection program in Austria. 

The two electric-arc furnaces will enable voestalpine to produce roughly 2.5 million tons of carbon-reduced steel by the year 2027, roughly 1.6 million tons in Linz and 850,000 tons in Donawitz. Learn more about greentec steel here.