ArcSave® electromagnetic stirring for AC electric arc furnace
Driving efficiency and sustainability in steelmaking
Overview
ArcSave® from ABB brings advanced electromagnetic stirring to AC electric arc furnaces, helping steelmakers tackle rising energy costs, decarbonization goals, and quality demands. By enabling rapid melt homogenization and more stable arc conditions, ArcSave improves operational consistency, reduces resource use, and supports safer, more sustainable steel production. Proven in 165+ installations worldwide, including some of the largest EAFs, this non-contact technology delivers long-term reliability backed by ABB’s metallurgical expertise and lifecycle support.
Typical benefits
Boost productivity by 5–7%
Faster scrap melting and shorter tap-to-tap times increase throughputCut energy use by 3–5%
Better heat transfer and arc stability reduce electrical energy consumptionReduce carbon emissions by 3-5%
Better heat transfer, faster melting, and less electrode wear cut footprintAchieve 1% higher yield
Faster melting, less oxidation, and better slag control improve yieldLower material use
Decreased alloy, additive, electrode and refractory consumption reduce costs and maintenance needsPayback often under 12 months
Typical ROI of 12–18 months can be as short as 12 months including productivity gains.Features
Explore the core design and control capabilities that make ArcSave unique. From non-contact installation and full-bath stirring to integrated automation and expert global support, these features ensure reliable performance and long-term value for AC electric arc furnace operations.
-
Versatile application for modern EAF designs and steel grades
ArcSave is engineered for flexibility, making it suitable for today’s ultra-high-power AC electric arc furnaces and continuous charging setups such as Consteel™. It supports a wide range of furnace configurations, including bucket-charged, EBT, and spout designs, and is proven for carbon steel, stainless steel, and specialty grades. This adaptability ensures optimized stirring performance for diverse steelmaking processes.
-
Full-bath stirring for homogeneous melt
ArcSave creates a powerful electromagnetic force that stirs the entire melt bath, eliminating dead zones and hot spots. This accelerates scrap melting, improves temperature and chemical uniformity, and supports consistent steel quality.
-
Non-contact installation for maximum reliability and safety
ArcSave is installed on the furnace bottom without physical contact with the molten steel, minimizing wear and maintenance. This non-contact design not only ensures long service life and reduced downtime but also eliminates the risk of melt breakout or refractory damage, common concerns with bottom gas stirring technologies. The result is safer, more reliable EAF operation under demanding conditions.
-
Seamless integration with the furnace control system
ArcSave’s automated stirring profile is fully integrated with the furnace control system, enabling precise, step-specific adjustments for melting, refining, and tapping. This ensures repeatable operations and improved process safety.
-
Proven technology with global installed base
Typical improvements with ArcSave are backed by 165+ installations worldwide, 80+ years of electromagnetic innovation and a performance warranty that guarantees results.
-
Expert global support and metallurgical know-how
ABB's Metallurgy team includes in-house metallurgical expertise and a dedicated aftersales team offering lifecycle services and support worldwide. From commissioning to optimization, you can benefit from tailored support that maximizes performance and ROI.
What our EAF metallurgy experts say
“ArcSave helps reduce the risk of furnace wear, scrap cave-ins and carbon boiling out, contributing to a safer working environment.”
"ArcSave can help to double the decarburization rate, which is particularly relevant when charging the EAF with hot metal or pig iron, or where decarburization is currently a bottleneck."
"We've seen ArcSave reduce electrode current swings by 50-60%, resulting in 6-8% lower electrode consumption, shorter process time and electrical energy savings."