Primetals: Successful upgrade of 118-ton electric arc furnace (EAF) at NLMK plant

Primetals Technologies has successfully upgraded a 118-ton electric arc furnace (EAF) at NLMK Indiana's steel plant in Portage, Indiana, U.S.A. The project, which involved a six-week shutdown period, resulted in a rapid and efficient startup, with the furnace achieving over 20 heats per day just four days after resuming operations. The furnace has since demonstrated consistent performance, exceeding 5,000 heats.

The success of the project was attributed to thorough planning, detailed preparation, and close collaboration during the implementation phase, ensuring a smooth and timely startup.

Enhanced Safety and Simplified Maintenance

NLMK Indiana sought to improve safety and streamline maintenance processes for its furnace operators. Primetals Technologies addressed these needs with a solution that includes a single-point roof-lifting system and an integrated gantry. These innovations reduce the need for physical access to the furnace roof during maintenance tasks, such as replacing the delta or lifting off the roof, thereby enhancing operator safety.

The delta replacement process is now faster, taking less than an hour, which reduces maintenance-related downtime and boosts overall productivity.

Proven Technology and Comprehensive Upgrade

NLMK Indiana selected Primetals Technologies for this project based on the company's extensive experience and successful track record with similar EAF upgrades. The scope of the upgrade included a new tilt frame, electric conductive arms, a roller bearing, a single-point roof-lifting system with an integrated gantry, a new roof, a hydraulic system, and a Level 1 automation system for the hydraulic operations. Some existing components, such as the lower and upper shells, were retained and integrated into the new system.

NLMK Indiana, part of NLMK USA, produces a range of steel products, including hot-rolled and pickled and oiled steels, primarily serving markets in pipe and tube manufacturing, energy, agriculture, construction, and automotive sectors. The plant is strategically located near the Port of Indiana on the shores of Lake Michigan. NLMK USA operates three production facilities in Pennsylvania and Indiana, with a combined annual output of 2.7 million tons of steel and over 1,100 employees.

Source and Photo: Primetals