SENNEBOGEN delivers material handlers made from “green steel”

The color green is currently of enormous importance; green stands for forward-looking, resource-saving, sustainable, efficient, progressive ...

In addition to green electricity and green cement, green steel is also frequently in the positive headlines. The recovery team had the opportunity to take a closer look at this topic at Salzgitter AG and its subsidiary, Deutsche Erz- und Metall-Union GmbH (DEUMU). And this article will also explore what green steel has to do with the SENNEBOGEN 830 G material handler, the 40-ton recycling excavator of the new machine generation.

Production of pig iron began in the northern Harz foreland 150 years ago. The Ilseder Hütte was founded in 1858 to smelt regional iron ore. The company developed successfully. With the takeover of the Peiner Walzwerk rolling mill and the early use of the Thomas process, the company became a major mining and steel group. From the 1950s onwards, rising costs and international competitive pressure finally led to a merger with Salzgitter AG in 1970 to form Stahlwerke Peine-Salzgitter AG. The global steel crisis led to major restructuring, the decline of the Ilsede site, and the discontinuation of the company‘s own ore mining operations.

In 1989, the group was privatized and later renamed Preussag Stahl AG. In 1998, the IPO gave rise to the new Salzgitter AG, which has since grown into a modern steel and technology group – among other things through the acquisition of Mannesmannröhren-Werke (2000) and Klöckner-Werke (2007).

In the future, it will be particularly important to drastically reduce CO₂ emissions, especially in energy-intensive industries, in order to remain competitive. Salzgitter AG and its subsidiary DEUMU (Deutsche Erz- und Metall-Union GmbH) have been committed to CO₂-reduced steel production for many years.

DEUMU was founded in Berlin in July 1941. Its purpose was to supply the steelworks in Salzgitter and other steelworks belonging to the Montanblock with ores, ferroalloys, non-ferrous metals, and other metallurgical raw materials. Today, DEUMU is a scrap and metal supplier for the Salzgitter Group, provides logistics and purchasing services for companies within the Salzgitter Group and third parties, and operates a qualified cutting facility for heavy plate, including complex processing services, as part of its steel processing activities.In order to reduce CO₂ emissions, Salzgitter is focusing on the SALCOS^® transformation program (Salzgitter Low CO₂ Steelmaking) transformation program. The aim is to produce steel in a “greener” way and to support customers on their way to a low-CO₂ value chain. By gradually converting production to low-CO₂ processes, Salzgitter AG plans to reduce emissions from steel production by up to 95 %.

The recovery team had the opportunity to take a quick tour of the site, where the path to climate-neutral steel production was clearly visible. Afterwards, the mystery surrounding the green SENNEBOGEN 830 G material handler was revealed. It was unloading a barge loaded with scrap metal for further processing. The material was destined for Deutsche Erz- und Metall-Union GmbH.

But it‘s not just the exterior paintwork of the 40-ton SENNEBOGEN recycling excavator from the new generation of machines that is green. The steel used to manufacture the material handling machine is also CO₂-reduced, “green” steel. It was unveiled for the first time at bauma 2025. CO₂ can be saved not only through efficiency and durability, but also during production. Salzgitter AG produces CO₂-reduced steel under the SALCOS^® brand – by using 100 % recycled scrap and green electricity from renewable sources. DEUMU, which has a long-standing partnership with SENNEBOGEN, used this steel to manufacture steel components for the new SENNEBOGEN 830 G material handler. Compared to conventional steel production, this CO₂-reduced steel enables CO₂ savings of more than 70 %.

Now the material handler itself is being used for steel scrap handling, thus closing the cycle. As a product development of the latest SENNEBOGEN machine generation, the new 830 G material handler also operates around 20 % more efficiently and saves a further 18.5 tons of CO₂ per year in operation compared to its predecessor model.

Marko Klickermann, DEUMU operations manager, explained how this joint project came about and what experiences have been gained with the green 830 G in an interview with the editor-in-chief of recovery magazine, Dr. Petra Strunk.

recovery: Green steel is now on everyone‘s lips, but many people do not understand the complexity behind it. Why does this topic play such a central role for Salzgitter AG?

Marko Klickermann: Because it is not a trend, but a necessity. European industry – and the steel industry in particular – is undergoing a fundamental transformation. Steel production is one of the most emission-intensive industries, and political climate targets clearly define that we must drastically reduce our CO₂ emissions.

Traditionally, steel production has been based on coal: it serves as a reducing agent to remove oxygen from iron ore and thus produce pig iron. This inevitably generates large amounts of CO₂. Our goal is to completely rethink this step.

The transformation to hydrogen-based direct reduction is therefore not only an ecological issue, but also an economic and strategic one: we want to produce CO₂-neutral steel in the long term – on an industrial scale.

recovery: What does this transformation process look like in concrete terms?

Marko Klickermann: We are gradually replacing the traditional blast furnace-converter route with a new technology consisting of:

1. Direct reduction plant (DRI)

– In the future, iron ore will no longer be reduced with coking coal, but with green hydrogen.

2. Electric arc furnace (EAF)

– These replace the blast furnace converter process. EAFs require electrical energy and direct reduced iron (DRI) together with scrap as feedstock or, in the steel scrap route, up to 100% steel scrap is used.

Scrap plays a key role in this. It is considered CO₂-neutral in terms of carbon footprint because its CO₂ footprint has already been accounted for in the first product life cycle. Every ton of scrap we can use directly improves the carbon footprint of the end product.

At the same time, we have to cater to different product qualities: thin sheet metal has completely different requirements in terms of purity and alloying than, say, a structural steel girder. That‘s why we need a mixture of scrap and high-quality DRI for high-quality steel grades.

recovery: Despite everything, we keep hearing that the economic conditions are still uncertain. Why is that?

Marko Klickermann: The biggest problem is political and economic uncertainty. Modern technologies are available, and we are currently building a new steel plant into the existing plant while continuing operations — which is an enormous challenge.

But in the end, we need a market that accepts and pays for green steel. To achieve this, companies must have clear advantages when using low-carbon steel. These advantages, in turn, depend on certification models, CO₂ crediting systems, and reliable regulation.

The fact that limits are currently being discussed, for example, is not helpful. What is needed here is clarity and reliable framework conditions so that willingness to invest is not thwarted.

recovery: The idea of a material handler made of green steel seems innovative and symbolically powerful. How did this idea come about?

Marko Klickermann: We have been working with SENNEBOGEN for around 20 years. We buy material handling machines, and SENNEBOGEN in turn purchases customized sheet metal from us for machine construction.

The idea itself arose almost casually during a conversation when we were talking about bauma. Someone said, “A green material handler made of green steel – that would send a strong signal.” And the longer we talked about it, the clearer it became to us: “This is circular economy in action.”

The scrap is processed at our facility and goes into steel production. This produces gray or green steel. It is used to make sheet metal and cut-to-size blanks, which SENNEBOGEN uses to build machines, for example. These machines work for us – handling scrap. And this scrap metal is returned to the cycle. The cycle is complete – a machine made of steel that was already in our factory in a different form, so to speak.

recovery: Was the green excavator an experiment or a strategic move?

Marko Klickermann: A strategic and symbolic move. We wanted to show that the circular economy works in practice – not just as a concept.

It was important for us to demonstrate the technical feasibility, create a genuine product innovation, and provide visible proof that green steel is a truly usable industrial product.

SENNEBOGEN is the ideal partner for this because there is trust and a long-standing supply relationship between us. This meant that the project could be implemented quickly, openly, and without lengthy coordination processes.

recovery: Why did you decide to purchase a new machine now – and why did you choose a SENNEBOGEN machine again?

Marko Klickermann:The decision was based on three factors:

1. Long-standing, reliable cooperation since 2003

We have implemented many challenging projects together – in an industry that demands high performance and absolute reliability.

2. Extremely harsh operating conditions

Our handling machines run in three shifts, 365 days a year. After 8000 – 9000 operating hours, we routinely replace equipment to avoid downtime.

3. Suitable machine class

The SENNEBOGEN 830 is our “bread and butter machine.” It has to be versatile. We need it for filling rail cars, loading trucks, sorting, and feeding plants.

Larger machines would have been too bulky, smaller ones don‘t have enough reach. SENNEBOGEN has been delivering consistently high quality for years, and the machines are constantly evolving.

recovery: How has the technology of material handling machines changed over the last two decades?

Marko Klickermann: Very significantly. If you compare the machines from 2003 with today‘s machines, we are not talking about evolutionary steps, but revolutionary ones. Just look at the three main categories:

Comfort & ergonomics:

Air-conditioned full suspension seats

Soundproof cabins

Large touch displays

Individually programmable machine functions and operator profiles

intelligent assistance systems

Efficiency & environment:

Modern emission standards

Drastically reduced diesel consumption

Intelligent control systems for boom, engine, and hydraulics

Digital assistance:

360° surround cameras

Swivel limitation

Collision warning

Environment monitoring

Condition monitoring

Predictive maintenance

This is a quantum leap in terms of safety and efficiency.

recovery: Has this had an impact on accident figures or operator errors?

Marko Klickermann: Yes, definitely. In the past, it was relatively common to see damaged paneling, bent doors, or obstacles that had been hit. Today, that hardly ever happens.

The vision systems, cameras, and assistance functions support the operators so well that typical risks have been massively reduced. At the same time, the ergonomics improve concentration — many operators themselves say that the machines are more pleasant and intuitive to operate.

recovery: How important is the service provided by SENNEBOGEN and its partners for your business?

Marko Klickermann: It is essential; the functional guarantee in three-shift operation stands and falls with it. This includes fast spare parts supply, a responsive service team, and, of course, communication based on partnership. SENNEBOGEN offers uncomplicated, fast solutions in the event of machine downtime.

For us, it‘s not just the product that counts, but the overall package. When a machine breaks down, we need a solution within hours—not after a lengthy administrative process. This has been working excellently with SENNEBOGEN and our service partner Schlüter for years.

recovery: Looking to the future, what do you need to realize the full potential of green steel and modern handling technology?

Marko Klickermann: We are very well positioned on the technical side. Machines are becoming smarter, more energy-efficient, and safer. Steel production is in the midst of the greatest transformation in its history. What we urgently need, however, is political clarity and reliability. This includes fair framework conditions for low-carbon products, clear crediting mechanisms, planning security for investments, and, of course, social acceptance of green additional costs.

Only when all these factors come together can we continue on our path – and that is precisely why projects such as the green SENNEBOGEN material handler are so important: they show that change is possible, even on a real industrial scale.

recovery: Thank you very much for the open and informative conversation.