Primetals Technologies has been awarded a contract by Outokumpu Stainless USA to supply and install a 180-ton twin ladle furnace at its stainless steel production facility in Calvert, Alabama. The major upgrade will replace an existing ladle treatment stand commissioned in 2012 and is designed to improve operational flexibility, optimize temperature control and support lower-carbon stainless steel production.
The new twin ladle furnace will strengthen Outokumpu’s steelmaking capabilities by providing additional electrical heating capacity following the argon oxygen decarburization (AOD) process. The upgrade will enable more efficient process management and greater flexibility in handling production requirements while utilizing the plant’s existing layout and foundation for streamlined installation.
Outokumpu’s Calvert facility processes up to 100 percent stainless steel scrap in its electric arc furnace (EAF), followed by refining in the AOD converter. The addition of the upgraded ladle furnace technology will further enhance the plant’s ability to produce high-quality stainless steel with improved energy efficiency and reduced environmental impact.
Primetals Technologies’ scope of supply includes a range of advanced mechanical and automation systems, including a water-cooled ladle cover integrated with the swing gantry system, the company’s patented electrode conducting arm with high-current technology, automated argon lancing equipment, hydraulic systems, a power supply solution and Level 1 automation. The installation will also feature Primetals Technologies’ Melt Expert electrode control system.
Melt Expert enables dynamic monitoring and control of the melting process, improving operational stability, productivity and energy efficiency. By optimizing furnace performance and reducing process variations, the system helps minimize energy consumption and address challenges associated with high energy requirements in steel production. The upgraded twin ladle furnace is scheduled to begin operation in March 2028.
Primetals Technologies and Outokumpu Stainless USA have a long-standing partnership that includes the development and supply of Outokumpu’s advanced stainless steelmaking facility in Calvert. The single-line plant, featuring a 160-ton electric arc furnace, 180-ton AOD converter, twin 180-ton treatment stands and a single-strand slab caster, was successfully commissioned and received final acceptance in 2013.
Outokumpu is a global leader in sustainable stainless steel and is driving the transition toward a more circular economy. The company’s stainless steel products are manufactured using approximately 95 percent recycled materials and are fully recyclable, supporting applications across infrastructure, mobility, household appliances and other industries.
In the United States, Outokumpu operates one of the country’s most advanced stainless steel mills in Calvert, Alabama. The facility provides a broad portfolio of stainless steel products supported by technical expertise and customer-focused services. Outokumpu is the second-largest producer of sustainable stainless steel in the United States.
