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 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.