NLMK Indiana, a prominent U.S. steel producer, has recently commenced operations with its newly revamped 118-ton electric arc furnace at its steel plant in Portage, Indiana. The significant upgrade, executed by Primetals Technologies, has marked a substantial enhancement in both safety and productivity. The project was completed with a total shutdown period of six weeks, culminating in the successful first heat. Remarkably, within just four days of restarting, the furnace produced 21 heats, quickly surpassing the 5,000 heats milestone with consistent performance.
The success of this project can be attributed to meticulous planning and collaboration throughout the implementation phase. The efficient startup process was facilitated by detailed preparation, which ensured a smooth and swift commissioning of the revamped furnace. This rapid ramp-up not only underscored the effectiveness of the upgrade but also highlighted the reliability of Primetals Technologies' solutions.
One of the primary objectives of the revamp was to enhance safety and streamline maintenance procedures at the Portage site. Primetals Technologies addressed these needs through two key innovations: a single-point roof-lifting system and an integrated gantry. These features, developed by experienced specialists, significantly improve operator safety by eliminating the need for physical access to the furnace roof during maintenance operations. The single-point system allows for safer and more efficient replacement of the delta and roof components, reducing the time required for these tasks to under an hour.
The reduction in maintenance downtime directly translates into increased productivity for NLMK Indiana. With the previous equipment, maintenance processes were more time-consuming and hazardous, impacting overall furnace performance. The new system not only enhances safety but also optimizes operational efficiency, enabling the EAF to maintain high productivity levels.
NLMK Indiana's decision to partner with Primetals Technologies was influenced by the latter's solid reference base in similar EAF revamp projects. The comprehensive scope of supply for this upgrade included a new tilt frame, electric conductive arms, a roller bearing, the single-point roof-lifting system with an integrated gantry, a new roof, a hydraulic system, and a Level 1 automation system for the hydraulic components. Additionally, certain existing components, such as the lower and upper shells, were retained and integrated into the new system.
As a part of NLMK USA, NLMK Indiana is a key supplier of diverse steel products, including hot-rolled, pickled, and oiled steels. The plant, situated near the Port of Indiana on the shores of Lake Michigan, primarily serves markets such as pipe and tube manufacturing, energy, agriculture, construction, and automotive. NLMK USA, which operates three production facilities in Pennsylvania and Indiana, produces approximately 2.7 million metric tons of steel annually with a workforce exceeding 1,100 employees.
The successful revamp of the EAF at NLMK Indiana not only reflects the commitment to advancing steel production technology but also demonstrates Primetals Technologies' capability to deliver effective and efficient solutions for the steel industry.
