The steel industry produces 7-8% of global CO2 emissions — and every major steelmaker has now committed to net-zero targets between 2040 and 2050. The transition from BF-BOF to EAF and hydrogen-based DRI is not just an environmental imperative but an operational transformation that introduces entirely new equipment categories: hydrogen electrolysers, DRI shaft furnaces, carbon capture systems, green hydrogen storage, and electric arc furnaces operating on fundamentally different process chemistry than their fossil-fuel predecessors. Each of these new asset classes requires maintenance programmes that do not yet exist in most plants' CMMS systems — because the equipment itself is new. Plants that deploy green steel technology without simultaneously building the predictive maintenance infrastructure around it risk the worst of both outcomes: the capital cost of new equipment plus the unplanned downtime of assets with no maintenance history. iFactory's New Asset Onboarding and Compliance platform provides the maintenance framework for green steel equipment from Day 1 — with pre-built PM templates for EAF, DRI, hydrogen systems, and CCUS that accelerate the learning curve from years to weeks.
Green Steel Transition: Analytics for EAF & DRI Equipment
Support your green steel transition with iFactory. Manage new EAF, hydrogen DRI, and carbon capture system maintenance for net-zero steelmaking.
The Green Steel Pathway -- From BF-BOF to Net Zero
The transition happens in stages, and each stage introduces new equipment that needs maintenance infrastructure. iFactory provides pre-built PM programmes for every stage -- so your maintenance team is ready before the new equipment arrives. See green asset onboarding in action.
BF-BOF
NG-DRI + EAF
H2-DRI + Green EAF
Net Zero + CCUS
Green Steel Equipment iFactory Manages from Day 1
EAF (New Install)
Electrode system, transformer, water cooling, hydraulic tilt, off-gas system, refractory. Pre-built PM from first heat.
DRI Shaft Furnace
Reduction gas system, cooling circuits, burden distribution, pellet feed. Hydrogen-ready maintenance profiles included.
Hydrogen Electrolyser
PEM or alkaline stack condition, water purity, membrane integrity, power electronics. New asset class with dedicated PM templates.
CCUS System
Capture column, compressor train, CO2 pipeline, injection well monitoring. Compliance documentation auto-generated.
H2 Storage & Distribution
High-pressure tanks, piping integrity, leak detection, safety instrumented systems. Safety-critical PM scheduling.
Renewable Power Systems
Solar/wind integration, battery storage, grid connection, power quality monitoring for EAF demand profiles.
Why Generic CMMS Fails for Green Steel -- And How iFactory Solves It
SAP PM, Maximo, and general-purpose CMMS platforms have no pre-built maintenance templates for hydrogen electrolysers, DRI shaft furnaces, or CCUS systems. Building these from scratch takes 6-12 months of engineering time. iFactory ships with pre-configured PM programmes for every green steel asset class -- ready to deploy on Day 1 of equipment commissioning.
iFactory's AI Stack for Green Steel Assets
AI Camera Vision
Thermal imaging on EAF shells, DRI shaft furnace exteriors, and H2 system enclosures. AI detects refractory hotspots, insulation gaps, and hydrogen leak indicators before they become safety events.
AI Digital Twin
Virtual model of each green asset calculates remaining life from operating data. EAF refractory, electrolyser membrane, and CCUS compressor models predict intervention windows 4-10 weeks ahead.
PLC Integration
Direct OPC-UA feed from EAF Level 2, DRI process control, electrolyser BMS, and CCUS compressor PLCs. Every process parameter tracked without manual data entry.
SAP PM + Carbon Reporting
Every maintenance event logged in SAP PM. Carbon intensity calculated per heat from energy consumption and fuel mix data. Regulatory carbon reports auto-generated for EU ETS, EPA GHG, and equivalent frameworks.
What a Green Steel Project Director Said
We commissioned a 1.5 MTPA DRI-EAF complex and had iFactory's PM templates loaded before the first reduction run. Our maintenance team had zero learning curve on the new equipment -- every inspection, every calibration, every spare part was pre-configured. The alternative was 8 months of engineering work building PM schedules from OEM manuals.
Frequently Asked Questions
Does iFactory have PM templates for hydrogen electrolysers?
Yes -- pre-built templates for both PEM and alkaline electrolysers covering stack condition, water purity, membrane integrity, and power electronics. See the template library.
Can iFactory track carbon intensity per heat in real time?
Yes -- CO2 per tonne of steel calculated from energy, fuel mix, and process data per heat. Reports auto-generated for EU ETS, EPA GHG, and regional frameworks.
How does iFactory help with CCUS equipment maintenance?
Pre-built PM for capture columns, compressor trains, and CO2 pipeline integrity. Compliance documentation auto-generated for injection well monitoring requirements.
Does iFactory integrate with existing SAP PM for brownfield transitions?
Yes -- bidirectional SAP PM integration means new green assets sit alongside existing BF-BOF equipment in the same maintenance platform with zero migration effort.
Build Your Green Steel Maintenance with iFactory
PM templates for EAF, DRI, H2, and CCUS -- ready now.
