Swiss Steel Group’s first forging furnace has been converted to electric heating. This was also the first installation of its kind worldwide and marks another innovative milestone for the Swiss Steel Group on the path to the sustainable transformation of steel production. The electrification of the forging furnace alone can reduce greenhouse gas emissions by up to 3,000 tons per year at the Finkl Steel-Sorel plant.
Higher energy efficiency and availability
In addition to reducing CO2 emissions, the switch from natural gas to electricity also leads to increased productivity and savings in energy consumption. For example, modeling showed a significant reduction in heat loss and thus higher energy efficiency. A more stable process, improved plant availability, and reduced maintenance requirements are also expected. Another advantage stems from the reduction in steel oxidation in the furnace: electric heating produces less scale and thus less material loss.
The switch to electric furnace technology also has a positive impact on employee health and safety: electric heating furnaces are safer to operate, air quality in the plant is improved, and dust levels are lower. Additionally, the electric forging furnace is safer to handle and easier to maintain.
Same performance, highest quality
All these advantages are achieved while maintaining the highest quality standards (temperature homogeneity, etc.) with the same heating capacity as in the gas-fired furnace. This was already demonstrated by simulations and feasibility studies conducted in advance, which were developed in collaboration with scientists at the Research Chair at ETS University (École de technologie supérieure) in Montreal. They specialize in applied teaching and research in engineering as well as the transfer of advanced technologies to companies.
As part of the conversion, all burners and natural gas-related components were removed and 36 tubular heating elements were installed, capable of withstanding temperatures up to 1,600 °C. In addition, new electrical controls were installed to supply the furnace with 1.4 MW. Another innovation is the use of a new refractory material that has the same insulating properties as ceramic wool but emits no pollutants.
Work on the project began in 2022 with comprehensive preliminary studies, and external suppliers were contracted in early 2025. Construction work began in May of last year and was completed by the end of the third quarter. Commissioning and testing took place from September to November, with the official handover to production in December 2025. This project was made possible by financial support from the province of Quebec.
Electrified Process Chain
The facility is powered by 100% hydroelectricity – one of the lowest-emission forms of energy generation – further strengthening the environmental performance of the site. In the new electric forging furnace at Finkl Steel-Sorel Québec, ingots weighing up to 40 tons can be heated before being forged on a press that was also recently upgraded and then further processed. The entire process chain, from the electric arc furnace to the heat treatment facilities, can now be powered electrically, enabling the company to offer customers high-quality, low-emission steel products.
The plant in St-Joseph-de-Sorel specializes in tool steels and high-grade engineering steels. The facilities can forge and heat-treat workpieces of a wide variety of shapes and sizes by customer requirements with their 2 open-die press of 2000 tons and the new one of 6700 tons.
Olivier Lebrun, CTO of the Swiss Steel Group: “The first electric forging furnace in our group is a prime example of ‘Forging the future.’ It paves the way for the further electrification of larger furnaces, enabling us to continuously and sustainably reduce our carbon footprint in line with our decarbonization roadmap. The transition to this furnace technology is a groundbreaking engineering achievement and sets the standard for the Swiss Steel Group and the entire steel industry.”