Systems Group, based in Maesteg, will carry out critical structural work and pipework replacement on Port Talbot’s two continuous casters – an essential part of the steelmaking process, turning liquid steel from the Electric Arc Furnace into solid steel slabs.
Credit: Tata Steel
The scheme is a key part of Tata Steel UK’s £1.25 billion transition to greener steelmaking.
The life-extension of the continuous casters will support the journey to sustainable low CO2 steelmaking as the business prepares for the commissioning of a new state-of-the-art electric arc furnace (EAF) by the end of 2027. Once operational, the EAF is expected to reduce Port Talbot’s carbon emissions by approximately 90%, equivalent to 5 million tonnes of CO₂ per year.
Ian Ellis, Engineering Project Manager at Tata Steel and lead on the caster life-extension, said: “This is a hugely important project for Port Talbot and for Tata Steel’s future in the UK. The casters are where liquid steel – produced at more than 1,600 degrees Celsius – is solidified into slabs, ready for further processing.
“This work will ensure our existing casters are in the very best condition to handle steel from our new electric arc furnace in the volumes and qualities demanded by our customers. Importantly, we can retain refurbish and replace these critical facilities rather than having to build from new, saving considerable cost and time.
“We’re delighted to be working with Systems Group – a trusted local partner – on this first phase of work.”
Ryan O’Neill, Managing Director at Systems Group, said: "We are delighted to have been awarded this important contract by Tata Steel. As a local company, we are proud to play a role in helping secure the future of steelmaking in South Wales.
This project not only supports the region’s economy but also helps deliver cutting-edge, low-carbon steel production.”
The caster project will include replacement of over 1.5 miles of key pipework and two giant water tanks.
In future phases there will be further replacements of equipment, structures and pipework as well as the installation of advanced technologies such as variable-speed-drives and next-generation process control systems.
Following the appointment of Systems Group, Tata Steel expects to award further contracts in the coming months for additional electrical mechanical and process control system upgrades.