​​Turning scrap into strength: Bekaert investigates hidden challenges in sustainable steel​

Traditional steel production relies heavily on iron ore and coal. To reduce emissions, manufacturers are increasingly adopting Electric Arc Furnace (EAF) technology. EAFs offer two major advantages: they emit less CO₂—especially when powered by renewable energy—and they can incorporate higher percentages of scrap steel compared to the conventional Basic Oxygen Furnace.

However, this transition isn’t without complications. To fully capitalize on EAF’s potential, the industry must address the unique challenges it introduces—particularly those linked to scrap steel.

Recycled steel, especially from everyday items like cars and appliances, often contains trace amounts of unwanted metals known as tramp elements. These include copper, chromium, nickel, molybdenum, and tin. Introduced through scrap, tramp elements can disrupt both the manufacturing process and the final product’s performance.

Their impact is felt in two key areas:.

To support the transition to sustainable steel, Bekaert launched a major research initiative in 2024. Its mission: to understand how tramp elements affect steel wire production and develop strategies to mitigate their impact.

This effort is spearheaded by the Metallurgy Expertise Center at Bekaert’s TechCampus, in collaboration with three key partners:

• Wire rod suppliers – providing the EAF steels
• OCAS NV (OnderzoeksCentrum voor de Aanwending van Staal) – a Belgian research institute focused on advanced metallurgy, producing test samples with accurately controlled levels of tramp elements for this study.
• University of Lille / Centrale Lille (France) – using advanced modeling software to simulate steel behavior during processing

The Flemish Government is also supporting the initiative, funding 50% of the project through VLAIO (Flanders Innovation & Entrepreneurship).

A central focus of the research is on the pearlitic transformation—a critical change in steel’s internal structure during heat treatment that determines wire strength and formability. This transformation occurs during patenting, a specialized heat treatment step that prepares steel for wire drawing.

Bekaert’s findings show that tramp elements slow down this transformation, potentially altering the steel’s behavior in later stages. Armed with these insights, Bekaert is refining its processes to ensure consistent, high-quality wire—even when using steel composed almost entirely of scrap.

Bekaert’s research is laying the groundwork for more sustainable steel wire production without sacrificing performance. By addressing the hidden challenges posed by tramp elements, the company is:

• Driving the global shift toward low-carbon emission steel
• Maintaining reliable product quality
• Supporting customers in achieving their sustainability targets
• Advancing its own environmental commitments

As demand grows for higher scrap content in steel products, new challenges continue to emerge on the path toward more sustainable production. While steel is infinitely recyclable, the quality of scrap inevitably declines over time as it circulates through diverse applications. Understanding the influence of tramp elements—and developing the agility to adapt manufacturing processes accordingly—is essential to anticipate and overcome future hurdles.

At the same time, promising opportunities are on the horizon. The increased use of renewable energy to power Electric Arc Furnaces, particularly through green hydrogen, offers a powerful lever to further reduce emissions. There’s also significant room to expand EAF-based production: while it accounts for 69% of steel output in the United States, it remains at just 45% in Europe and 10% in China.

In addition to its research on tramp elements and its commitment to increasing the scrap content in recycled steel, Bekaert also explores alternative pathways and emerging technologies for producing low CO2 emission steels aiming to support the industry’s transition to climate-neutral solutions.