Revolutionizing EAF Efficiency: Advanced Injection Technology in the Steel Industry with Delta Ducon and Clyde Pneumatic Conveying

By Matthew DelPizzo, Delta Ducon | Official North American Partner of Clyde Pneumatic Conveying Technology

In the high-stakes environment of modern steelmaking, the efficiency of the Electric Arc Furnace (EAF) is paramount. As steel producers face increasing pressure to decarbonize, reduce cycle times, and optimize slag foaming, the precision of material injection has become a critical differentiator.

Delta Ducon, a leader in bulk material handling with over a century of engineering excellence, is proud to stand as the official North American Partner of Clyde Pneumatic Conveying Technology. Through this strategic partnership, we are bringing the world-renowned RotoFeed injection technology to the North American steel market, offering a level of accuracy and reliability that traditional systems simply cannot match.

The Challenge: Precision in a Harsh Environment

EAF furnace cycles are complex. To maximize efficiency, operators must inject carbon and other additives (such as lime, ferro silicon, and ferro chrome) directly into the mix. This process drives slag foaming—essential for insulating the arc, protecting the refractory lining, and improving energy efficiency.

However, many brownfield Mills currently rely on outdated injection vessels with fluidizers and inconsistent valve trains. These systems often suffer from:

·         Inconsistent Feed Rates: Leading to poor slag foaming and energy waste.

·         High Maintenance Costs: Due to abrasive wear on valves and lines.

·         Lack of Control: Inability to fine-tune injection based on real-time furnace conditions.

Clyde RotoFeed Technology

As the exclusive partner for Clyde Pneumatic Conveying in North America, Delta Ducon offers the RotoFeed system—a revolutionary approach to EAF injection. Unlike traditional fluidizing systems, the RotoFeed utilizes a rotary feeder mechanism designed specifically for the pneumatic injection of pulverized materials against pressure.

Key Technical Specifications

Based on proven deployments in the Iron & Steel sector, the RotoFeed system delivers:

·         Feed Accuracy: +/- 5% by weight, ensuring precise chemical control.

·         Operating Pressure: Capable of discharging at 1.0 – 1.5 Barg.

·         Injection Rate: Typical operating rates up to 10 tph (tonnes per hour).

·         Material Versatility: Handles Pulverized Coke, Lime, Ferro Alloys, and EAF Dust (Particle size d50 = 500 microns).

·         Reliability: Designed for intermittent duty (24/7, 365 days/year availability).

The RotoFeed Advantage

The RotoFeed system represents a shift from "controlled chaos" to "precision engineering."

Pressure Balanced: The system operates as a pressure vessel, allowing materials to be fed directly into the conveying line without the blow-back associated with rotary valves in high-pressure lines.

Multi-Line Injection: The RotoFeed is available with 1, 2, or 3 outlets. Crucially, individual lines can be shut off without affecting the flow rate of the others—a massive advantage for multi-point injection strategies (e.g., combining Lances, Oxygen Burners, and Side Block Jets).

Active Dispensing: Instead of relying on passive fluidization, the RotoFeed actively dispenses material into the air stream, guaranteeing a consistent fuel-to-air ratio.

Retrofit Capabilities: Upgrading Brownfield Mills

For steel Mills with existing infrastructure, a full system tear-down is often unfeasible. Delta Ducon provides RotoFeed Retrofit Kits designed to modernize existing injection systems.

We have successfully engineered many retrofits for competitor vessels and injectors.

We remove the existing fluidizer and downstream valve train and replace them with a custom adapter and the RotoFeed unit.

Integration: We utilize existing instrumentation and air flow management where possible to reduce

Why Partner with Delta Ducon?

The steel and metals industrylook for authority and trust. When you choose Delta Ducon, you are not just buying a piece of equipment; you are leveraging:

100+ Years of Material Handling Expertise: Delta Ducon’s legacy in American engineering.

Global Innovation: Clyde Pneumatic Conveying’s 50 years of dense phase leadership.

The future of Green Steel relies on precision. By integrating Clyde Pneumatic Conveying’s RotoFeed technology, North American steelmakers can achieve tighter control over their EAF cycles, reduce additive waste, and improve energy efficiency.

Delta Ducon is ready to assess your current injection systems and design a retrofit or greenfield solution that meets the demands of modern steel production.

For More Information Visit: www.DeltaDucon.com