Systems Spray-Cooled Recently Completes BRS Phase II Melt Shop Expansion

Systems Spray-Cooled Recently Completes BRS Phase II Melt Shop Expansion

May 2021 Nashville, TN

As part of its Phase Two expansion that was recently completed, Big River Steel in Osceola, Arkansas installed and commissioned new Spray-Cooled™ on furnace electric arc furnace (EAF) equipment including a roof, elbow, sidewall and off-gas duct work with Systems Spray-Cooled from The Systems Group.

The EAF roof is a gantry style roof with a steep cone hot face profile for optimization and extended lifetime. The elbow incorporates a new integrated drain design that eliminates bolted connections for quicker change outs. The EAF sidewall incorporates a unique proprietary hot face profile that includes integrated ‘bump-outs’ to help protect the burners and refractory bricks, and reduce scrap jams at the slag door opening area.

As part of the project, Systems Spray-Cooled partnered with SMS Group to provide a complete Spray-Cooled™ Direct Evacuation Control System (DECS) consisting of a D1 downcomer duct, Drop-out Chamber (DOC) and downstream duct for all the water-cooled equipment. The D1 downcomer duct is hydraulically actuated on a fixed rail support system that allows for real-time air gap adjustment. The DOC is a panelized, self-supported design consisting of 20 sidewall and roof panel segments, a hydraulically actuated access door for cleanout, and a manually actuated emergency exit access man door. The downstream duct includes an electric driven actuator, and 12 sections of duct work (D2 through D13) totaling 236 feet in length and including a support structure tower with access platforms and ladders for the vertical duct section. Big River Steel expects the spray-cooled duct work will cool the off-gas more efficiently than typical tubular duct work. In all, 33 pieces of spray-cooled equipment were installed and commissioned at Big River Steel for the Phase Two expansion.

Big River Steel’s decision to install Spray-Cooled™ equipment was based on the need for the safest, most reliable solution when considering long term maintenance costs.

For further information, contact The Systems Group, 214 N. Washington Ave. Ste 700, El Dorado, AR 71730; phone 870-862-1315; web spraycooled.tsg.bz; email info@tsg.bz.

Nucor Steel Brandenburg EAF Furnace

Systems Spray-Cooled receives contract from Nucor Steel Brandenburg

Systems Spray-Cooled receives contract from Nucor Steel Brandenburg

December 2020 Nashville, TN

Systems Spray-Cooled, of The Systems Group, was selected to supply the electric arc furnace (EAF) Spray-Cooled™ equipment to Nucor Corporation’s new plate mill in Brandenburg, KY.  The new EAF greenfield project includes equipment for a single EAF operation.  The Spray-Cooled™ equipment will include 100% of Nucor’s on furnace cooling needs, to include the EAF shells, roofs, and fume elbows.  The EAF roof will be a single-point cantilever roof lift design with flanged bolted gantry connection and a steep cone hot face profile for optimization and extended lifetime.  The elbow will incorporate a new integrated drain design that eliminates bolted connections for quicker change outs.  The EAF sidewall will incorporate a unique proprietary hot face profile that includes integrated ‘bump-outs’ to help protect the burners and refractory bricks and reduce scrap jams at the slag door opening area.

“We are pleased to continue our successful partnership with The Systems Group on one of our company’s largest capital investment projects,” said Johnny Jacobs, Vice President & General Manager of Nucor Steel Brandenburg.  “When operational, this state-of-the-art mill will have the most diverse product offering of any plate mill in North America.”

For further information, contact The Systems Group, 214 N. Washington Ave. Ste 700, El Dorado, AR 71730; phone 870-862-1315; web spraycooled.tsg.bz; email info@tsg.bz.

Systems Contracting Advances 9 Positions – ENR Top 600 Specialty Contractors

Systems Contracting advances 9 positions to #341 in the 2020 Engineering News-Record’s Top 600 Specialty Contractors.

El Dorado, Ark., November 19, 2020 – Systems Contracting Corporation, a leading contractor serving the industrial, municipal and commercial construction markets, has been named one of the Top 600 Specialty Contractors nationwide in an annual ranking report released by Engineering News-Record (ENR), a leading U.S. construction/engineering industry publication. Ranked #341 – 9 positions higher than last year – Systems Contracting is the highest-ranked Arkansas firm on the list and has been part of the ENR “Top 600” for many consecutive years. Continue reading “Systems Contracting Advances 9 Positions – ENR Top 600 Specialty Contractors”

Systems Spray-Cooled Delivers Equipment to Nucor Steel Gallatin

Systems Spray-Cooled Delivers Equipment to Nucor Steel Gallatin

September 2020 Nashville, TNNucor Steel is expanding the steelmaking capacity at its flat-rolled sheet steel mill located in Ghent, KY.  As part of the expansion project, Nucor is adding a new 175-ton EAF that will increase the mill’s annual capacity from 1.6 million tons to approximately 3 million tons of coiled steel.

Systems Spray-Cooled, of The Systems Group, was selected to supply the new EAF and has delivered its first shipment of Spray-Cooled™ equipment to Nucor Steel Gallatin.   The Spray-Cooled™ equipment will include 100% of Nucor’s on furnace cooling needs, to include the EAF shells, roofs, and fume elbows.  The EAF sidewall will incorporate a unique proprietary profile that includes integrated ‘bump-outs’ to help protect the burners and refractory bricks and reduce scrap jams at the slag door opening area.  The roof will be a new steep cone design for optimization and extended lifetime.  The elbow will incorporate a new integrated drain design that eliminates bolted connections for quicker change outs.  Both the sidewall and roof will have an integrated Resistive Temperature Detector (RTD) system to enable zone monitoring of water temperatures throughout the furnace.  

Nucor’s decision to install Spray-Cooled™ equipment was based on the success they have seen at their other EAF shops and on the need for the safest, most environmentally friendly, lowest cost option (supply and maintenance) along with the extended life and performance for water-cooled equipment.

For further information, contact The Systems Group, 214 N. Washington Ave. Ste 700, El Dorado, AR 71730; phone 870-862-1315; web spraycooled.tsg.bz; email info@tsg.bz.  

Systems Spray-Cooled receives an order to upgrade Optimus Steel EAF

Systems Spray-Cooled receives an order to upgrade Optimus Steel EAF

July 2020 Nashville, TN — Optimus Steel has placed an order for a furnace upgrade solution with Systems Spray-Cooled of The Systems Group.  The 4th quarter 2020 turn-key project includes a new Spray-Cooled™ Electric Arc Furnace (EAF) Roof, a new Spray-Cooled™ Elbow, the accompanying equipment that will replace its existing tubular equipment, and a complete engineering package that covers a laser scan of the entire melt shop, design and layout all of the piping, and engineering of the required infrastructure changes.  

The engineering portion includes modifying their current 4-point gantry lift roof to a 2-point gantry lift design.  By removing the (2) existing long gantry arms and replacing them with customized short arms, Optimus Steel will eliminate the associated downtime and maintenance issues with their old gantry arms design.  The new design will address current operational issues and will allow for better roof alignment and delta changes.  The elbow spray water will be supplied and drained from the roof minimizing hoses and connections.  The roof diameter will be oversized to allow for a larger furnace sidewall in the future.   This project is expected to be the first phase of a multi-phase melt shop upgrade to a more optimized design with the upper shell and off-gas system to follow.  

Optimus Steel, located in Beaumont, Texas, produces a wide range of high-quality wire rods, coiled rebar, and billets. This mill has been recognized with awards for safety, community service, outstanding engineering, and environmental improvement throughout the years. Optimus Steel is logistically situated near Houston to provide value added solutions that help their customers in the construction, automotive, energy, consumer, and manufacturing markets.

Optimus Steel’s decision to install Spray-Cooled™ equipment was based on the need for the safest, most environmentally friendly, lowest cost option (supply and maintenance) along with the extended life and performance for water-cooled equipment. 

For further information, contact The Systems Group, 214 N. Washington Ave. Ste 700, El Dorado, AR 71730; phone 870-862-1315; web spraycooled.tsg.bz; email info@tsg.bz.  

SprayCooled Furnace EAF Charge

Systems Spray-Cooled receives order from Steel Dynamics, Inc.

Systems Spray-Cooled receives order from Steel Dynamics, Inc.

June 2020 Nashville, TNSystems Spray-Cooled has received an order from Steel Dynamics, Inc. for Spray-Cooled™ equipment at their new mill in Sinton, TX currently under construction.   The 2021 project includes equipment for their (2) Electric Arc Furnaces.  The Spray-Cooled™ equipment will cover 100% of SDI’s furnace cooling needs and will include the EAF shell, roof and elbow.  The EAF sidewall will incorporate new ‘bump-outs’ to help protect the burners and refractory bricks.  The roof will be a new steep cone design for optimization and extended lifetime.

SDI’s decision to purchase Spray-Cooled equipment was based on the success they have seen at their other EAF shops and on the need for the safest, lowest cost option (supply and maintenance) along with the extended life and performance for water-cooled equipment.

For further information, contact The Systems Group, 214 N. Washington Ave. Ste 700, El Dorado, AR 71730; phone 870-862-1315; web spraycooled.tsg.bz; email info@tsg.bz.  

Top 600 ENR Specialty Contractor 2019

The Systems Group Named a Top Specialty Contractor

Arkansas Company #350 in 2019 ENR Top 600 Specialty Contractors Ranking

El Dorado, Ark., October 2019 – The Systems Group (tsg.bz), a leading specialty contractor serving the industrial market with a focus on steel mills, has been named one of the Top 600 Specialty Contractors nationwide in an annual ranking report released by Engineering News-Record (ENR), a leading U.S. construction/engineering industry publication. Now ranked #350 – it is the 2nd highest-ranked Arkansas firm on the list and has been part of the ENR “Top 600” for nine consecutive years.  Construction services are provided through the company’s specialty contracting unit, Systems Contracting Corporation (contracting.tsg.bz). The Systems Group does extensive work for steel mills, foundries and other facilities. The group’s numerous specialties include but are not limited to process piping, structural concrete, structural steel erection, equipment setting and alignment, plant maintenance services, boiler and pressure vessel installation, service and repair, and machining and fabrication services. Headquartered in El Dorado, Arkansas, The Systems Group also has division and field offices throughout the continental United States with equipment in over 90 installations in 18 countries worldwide. 

  For further information, contact The Systems Group, 214 N. Washington Ave. Ste 700, El Dorado, AR 71730; phone 870-862-1315; web tsg.bz; email info@tsg.bz.  

SprayCooled Furnace EAF Charge

Systems Spray-Cooled receives an order from Europe for a new Spray-Cooled™ EAF Roof and Elbow

Spray-Cooled EAF Roof and ElbowOctober 2019, Nashville, TNIndusteel Belgium sa (“Industeel”) has placed an order for a new Spray-Cooled™ Electric Arc Furnace (EAF) Roof and Elbow with Systems Spray-Cooled.  The 2020 design-build project includes a new EAF Roof, Elbow, engineering, laser scans, and accompanying equipment that will replace its existing tubular equipment.  The full scope, in conjunction with partner tripleS GbR, includes gantry and alloy chute modifications, and RTD monitoring. 

Industeel is a wholly owned subsidiary of ArcelorMittal Group located in Charleroi, Belgium.  They are a producer of stainless steel, high strength, and other corrosion resistant alloyed steel plates, leading the market in special alloyed plates for cryogenic service, oil and gas, and nuclear.    Industeel is a specialized producer of hot rolled as well as forged steel plate, ingots, and formed pieces, with the largest dimension range worldwide. The mill has been producing steel for nearly 200 years, dating back to 1836.

Industeel’s decision to install Spray-Cooled™ equipment was based on the need for the safest, most environmentally friendly, lowest cost option (supply and maintenance) along with the extended life and performance for water-cooled equipment.

For product information, go to https://spraycooled.tsg.bz/applications/eaf-roofs/. For general information, contact Systems Spray-Cooled at +1 (615) 366-7772; email info@tsg.bz web spraycooled.tsg.bz.

Jewett EAF Roof

The Systems Group is Making a BIG Economic Impact in Southern Arkansas

The Systems Group is Making a BIG Economic Impact in Southern Arkansas


April 3, 2018, El Dorado, Arkansas –
The Systems Group (TSG) is making a BIG difference in their hometown, manufacturing Spray-Cooled™ furnace equipment used in the steel making industry, one that in turn drives our national economy.  TSG started in El Dorado in 1972 by Charles Hays, Sr., and is proud to continue to create jobs in the ElDoArk area, with a focus on growth and development of the town itself.

One of four divisions of TSG, Systems Spray-Cooled, holds over 80 current or pending patents worldwide related to Spray-Cooled™ cooling technology.  This technology, which is in over 100 mills in 19 countries, enables steel mills to operate more safely with less downtime. 

The equipment (an electric arc furnace roof) in this picture is destined for a steel mill in Jewett, TX.  Systems Spray-Cooled™ equipment is fabricated all around the world; however, when logistics allow, their equipment is fabricated at TSG’s local fabrication shop, Systems Fab & Machine, located in their hometown of El Dorado, Arkansas.  Every piece that can be built in El Dorado brings jobs to our area that would not exist without Systems.  Due to the size of the equipment, logistics can be just as big of a project as manufacturing it!

TSG not only focuses on Spray-Cooled™ Technology but also has three additional divisions: Systems Plant Services helps maintain steel mills across the country; Systems Contracting offers contracting services locally and across the nation; Systems Fab & Machine offers fabrication and machining capabilities right here in El Dorado, Arkansas.  The latter two divisions were heavily involved with the construction of the new Murphy Arts District (MAD) in El Dorado.

TSG not only helps to stimulate our local economy, but they allow El Dorado, Arkansas to hold an international market and deliver a little bit of El Dorado, Arkansas across the world.  While operating worldwide, TSG maintains their roots and remains headquartered in El Dorado, Arkansas. 

 

For product information, go to https://spraycooled.tsg.bz/applications/eaf-roofs/. For general information, contact Systems Spray-Cooled at +1 (615) 366-7772; email info@tsg.bz web spraycooled.tsg.bz.

SprayCooled Furnace EAF Charge

Ovako Hofors Puts Safety at the Forefront with the First Spray-Cooled™ EAF Roof in the Nordic Region

Ovako EAF Spray-Cooled RoofJuly 24, 2017, El Dorado, Arkansas Swedish steel producer Ovako has awarded Systems Spray-Cooled the contract to modernize and increase safety on their Electric Arc Furnace (EAF) with the first Spray-Cooled™ roof in the Nordic region, located at their bar, billet, tube, and rings facility in Hofors, Sweden.

After first being exposed to Spray-Cooled technology at the European Electric Steelmaking Conference in Italy, Ovako weighed the new technology against their current pressurized tubular roofs.  The main concerns were implementing the technology with their environment (piping); otherwise, Ovako has been highly enthusiastic about the technology and saw clear advantages both for maintenance and for safety. Because Spray-Cooled™ equipment operates at atmospheric pressure, the cooling water is not pumped across the area to be cooled. Therefore, the potential for high pressure, high volume water leaks is eliminated.

Under the contract, the new roof will be engineered to work with their current furnace setup, as well as ‘future-proofed’ to integrate with planned furnace upgrades.  To alleviate concerns about potential piping issues, the new roof will be engineered using state of the art 3D laser scans of the current furnace and surrounding mill.  The 3D laser scan will aid in the design, especially since the available drawings are 25 years old and have discrepancies.  It will also allow piping to be designed accurately for easy fitment and should greatly reduce or eliminate unforeseen issues in the process.

The Hofors steelmaking operation, based around ingot casting, has an annual capacity of about 500,000 tonnes of ingots. The tube rolling capacity is about 120,000 tonnes annually and the ring rolling capacity about 45,000 tonnes a year.

This is an unconventional cantilever-lift roof that will be fabricated in Germany. Ovako and Systems plan on commissioning the new roof in January of 2018.   

For product information, go to https://spraycooled.tsg.bz/applications/eaf-roofs/. For general information, contact Systems Spray-Cooled at +1 (615) 366-7772; email info@tsg.bz web spraycooled.tsg.bz.