As global pressure mounts to decarbonise heavy industry, steel producers are facing one of the biggest transformations in their history. The steel sector currently accounts for around 7% of global CO₂ emissions – and with regulations tightening and stakeholder expectations rising, the call to shift to greener processes is no longer optional. It’s strategic.
Recent developments show the momentum is real. In June, Reuters published a deep dive into how hydrogen-based processes, electric arc furnaces, and next-generation technologies are reshaping global steelmaking. For UK manufacturers, this evolution is both a challenge and an opportunity – and success will hinge on having the right infrastructure, controls, and data in place to support low-carbon production.
What Is Green Steel?
Green steel refers to steel produced using low- or zero-carbon methods. This typically involves moving away from traditional blast furnace production (which uses coking coal) and embracing newer technologies like:
- Hydrogen-based Direct Reduced Iron (H₂-DRI)
This method uses green hydrogen instead of coal to extract iron from ore. It’s already being piloted by major European producers and could cut emissions by over 90% compared to conventional methods. - Electric Arc Furnaces (EAFs)
EAFs melt scrap steel using electricity – ideally sourced from renewables. It’s already a mature technology but is being modernised through automation and data integration. - Molten Oxide Electrolysis (MOE)
Still in early stages, MOE could eliminate the need for carbon inputs entirely. This electrolytic method separates iron from ore using electric current, producing only oxygen as a by-product.
What’s Driving the Shift?
- Policy pressure: With mechanisms like the EU’s Carbon Border Adjustment Mechanism, the cost of carbon-heavy steel will continue to rise.
- Investor expectations: ESG metrics are increasingly influencing supplier selection and investment decisions.
- Customer demand: Major OEMs and construction groups are looking for low-carbon material sources to meet their own net zero commitments.
Tata Steel & Control Metrix
Just last week (July 2025), Tata Steel marked a major milestone in the decarbonisation of British steelmaking by breaking ground at its Port Talbot site to begin the transformation to electric arc furnace (EAF) technology. The move is expected to dramatically reduce carbon emissions and position Tata as a leader in more sustainable, UK-based steel production, with operations targeted to commence by the end of 2027.
Control Metrix and our sister company have been long-standing technology partners to Tata Steel. Our ongoing work with leading manufacturers like Tata reflects our commitment to helping UK industry move forward — cleaner, smarter, and more efficiently.
Control Metrix: Supporting the Transition to Greener Steel
While headline focus is producing steel using low CO₂ emissions methods through adoption of electric arc furnaces or Hydrogen technologies, the backbone of this transition is precision – in temperature, energy usage, and process control. That’s where we come in.
At Control Metrix, we’ve worked with metals and steel manufacturers for nearly two decades, helping them integrate the advanced measurement and monitoring tools they need to future-proof their operations. Our technologies support this new generation of steelmaking in several key areas:
Our Impac pyrometers and thermal imaging systems deliver accurate, real-time temperature monitoring in extreme environments — including EAFs, hydrogen DRI units, and annealing furnaces. They help manufacturers optimise energy use, reduce waste, and maintain quality even as they trial new processes or fuels.
Our FurnaceSpection systems provide continuous thermal imaging from inside operating furnaces, allowing operators to spot inconsistencies before they become critical. In green steel setups, this data is crucial for maintaining thermal balance and protecting valuable refractory linings.
With SCR power controllers like those in the Advanced Energy Thyro-Family, manufacturers gain responsive, precise control over industrial heating systems. Whether working with electric furnaces, induction processes or thermal reformers, our systems support energy efficiency, soft-starting, and reduced harmonic distortion.
Using laser measurement systems provided by our sister company LIMAB UK for measuring the slab width, slab edge profile, and slab length control during the casting process.
From Data to Decision-Making
In this new era of steel production, visibility is everything. Whether you’re trialling green hydrogen, reconfiguring line speeds, or balancing energy loads in a mixed-source grid, your success depends on having the right real-time process data – and the control systems to act on it.
Control Metrix products integrate seamlessly with PLCs, SCADA, and data platforms, helping teams translate raw sensor data into actionable insights. That’s the foundation for informed, low-carbon decision-making.
Meet Us at UK Metals Expo
This September, we’ll be exhibiting at UK Metals Expo, where the future of steel and metals manufacturing – including low-carbon steelmaking – will be front and centre. Industry experts, including T. V. Narendran, Chair of the World Steel Association (worldsteel) and CEO & Managing Director of Tata Steel, will be headline keynote speaker at the event. If you’re planning your decarbonisation roadmap – or just want to understand what technologies will help you stay competitive in the years ahead – come speak to our team on stand A40, or call us today +44 (0)1823 761 309.
We’re ready to support your next step toward smarter, cleaner, more efficient manufacturing – contact us to discuss your requirements.
