A forward-thinking steel mill was grappling with a major challenge impacting its profitability: high and volatile energy costs. To remain competitive and meet its sustainability targets, the plant management initiated a program to reduce the overall energy consumed per ton of steel produced. They partnered with the technical experts at Pennekamp Middle East to perform a comprehensive “thermal audit” of their entire production line to identify key areas of energy loss.

The audit revealed significant opportunities for improvement in three main areas: the Electric Arc Furnace (EAF) roof, the steel ladles, and the billet reheat furnace.

Area 1: The Electric Arc Furnace – Retaining Melting Energy

• The Problem: The analysis showed that the EAF’s delta roof section was constructed from a material with poor insulating properties. A significant amount of thermal energy was being lost through the roof during the melting process, extending tap-to-tap times and increasing electricity consumption.
• The Solution: The existing roof was replaced with a high-performance, pre-cast refractory shape made from a high-alumina, low-conductivity castable. This new roof was specifically designed for superior thermal insulation.
• The Result: By retaining more heat inside the furnace, the scrap melted faster. This led to a measurable decrease in power-on time and a reduction in electricity consumption of 5% for the EAF.

Area 2: The Steel Ladles – Conserving Heat Between Processes

• The Problem: The mill’s ladles were experiencing a high rate of temperature drop, forcing them to tap the EAF at a higher “superheat.” This not only wasted energy at the EAF but also required more time and energy for temperature adjustment at the ladle furnace.
• The Solution: A new multi-layer lining was implemented, featuring a high-performance insulating brick layer against the ladle shell, complemented by a durable, thermally efficient working lining.
• The Result: The improved insulation reduced the average temperature loss significantly, allowing the required EAF tapping temperature to be lowered by 15°C.

Area 3: The Reheat Furnace – Optimizing for the Rolling Mill

• The Problem: The billet reheat furnace, a major consumer of natural gas, was found to have significant heat loss through its aging walls and roof.
• The Solution: The furnace was relined using a combination of advanced lightweight insulating firebricks (IFBs) and low thermal mass ceramic fiber modules.
• The Result: The new, highly efficient lining reduced heat loss to the atmosphere, allowing the furnace to heat up faster and maintain its temperature with less fuel. This resulted in a 10% reduction in natural gas consumption for the reheat furnace.

The Overall Impact: A Plant-Wide Success

By treating refractory linings as a strategic engineering system rather than a simple maintenance item, the steel mill achieved remarkable results. The combined upgrades led to a significant reduction in total energy consumption per ton of steel, a corresponding decrease in the plant’s CO2 emissions, and improved productivity due to faster cycle times. This case study proves that investing in advanced refractory materials is a powerful and effective strategy for sustainable and cost-effective steel manufacturing.

Unlock Energy Savings in Your Plant

Is your operation losing money to thermal inefficiency? The refractory experts at Pennekamp Middle East can help you identify and solve areas of energy loss throughout your plant.

Contact us today to schedule a thermal audit and discover how our advanced refractory solutions can lower your energy costs and improve your bottom line.