Over the past three years, the Berry Metal team has been collaborating closely with a valued customer in San Nicolás de los Garza, Mexico, to implement a comprehensive continuous improvement plan aimed at optimizing the performance of their existing Electric Arc Furnace (EAF). This long-term technology partnership began with the installation of Berry Metal V-Max™ Burners in two of the customer’s flat panel positions, setting the stage for a series of upgrades designed to drive efficiency, reduce operational costs, and improve overall productivity.
Stage 1: Introducing V-Max™ Burners
The initial phase of the project focused on enhancing the combustion process within the furnace. Berry Metal’s V-Max™ Burners were installed in two flat panel positions, replacing the previous burners. This upgrade significantly improved the combustion efficiency and chemical energy flexibility, laying the foundation for further optimization in the following stages of the conversion process.
Stage 2: Upgrading to DuraForge™ Copper Boxes
Building on the success of the V-Max™ Burners, the second stage of the project involved replacing the flat panels with Berry Metal DuraForge™ copper boxes. These advanced copper boxes, outfitted with V-Max™ Burners and BMC carbon air assists, provide superior heat management and durability, making them ideal for high-performance EAF operations. The DuraForge™ copper boxes helped to enhance the furnace’s overall efficiency and allowed for more precise control over the energy input and combustion process, further reducing fuel consumption and improving performance.
Stage 3: Installing DuraForge™ Sump Panel Technology
The final stage of the furnace conversion involved the installation of Berry Metal DuraForge™ sump panel technology, also outfitted with the V-Max™ burner. The sump panels are designed to withstand extreme conditions while effectively managing heat transfer and cooling. The addition of these panels completed the furnace’s transformation, enabling even greater control over the furnace environment, resulting in further reductions in energy usage and an increase in the overall productivity of the EAF.
Remarkable Results
The outcomes of this multi-stage furnace conversion project have been nothing short of impressive, with substantial improvements in various operational metrics, including energy savings and increased productivity. Notable achievements include:
- Water Leak Reduction: The installation of Berry Metal technology has led to a greater than 90% reduction in water leaks from 2019 levels and a more than 75% reduction from 2021, significantly improving furnace reliability and reducing maintenance costs.
- CO2 Emissions Reduction: The technology upgrades have contributed to a roughly 15% reduction in CO2 emissions, aligning the customer’s operations with sustainability goals and contributing to a cleaner environment.
- Energy Savings: The continued improvements in combustion efficiency and energy management have resulted in savings in carbon, natural gas, oxygen, and electricity utilization, lowering operating costs while increasing productivity and overall furnace efficiency.
| Variable | Unit | 2019 | 2020 | 2021 | 2022 | 2023 | Improvement |
|---|---|---|---|---|---|---|---|
| Electrical Energy | Kwh/TAL | -1.2 | -7.7 | -18.6 | -23.9 | -22.2 | 6% |
| Charcoal | Kg/TAL | -2.9 | -7.1 | -8.2 | -8.9 | -6.9 | 60% |
| Natural Gas | m³/TAL | 0 | -1.7 | -2.8 | -2.0 | -2.5 | 46% |
| Oxygen | m³/TAL | 0.5 | -3 | -5.9 | -5.1 | -2.1 | 15% |
| Electrodes | Kg/TAL | -0.01 | -0.1 | -0.3 | -0.3 | -0.32 | 17% |
| Productivity | TAL/hr | 0.9 | 2 | 3.8 | 7.6 | 7.5 |
A Proven Partnership for Continuous Improvement
This successful partnership between Berry Metal and our customer in Mexico is a testament to the power of collaboration and continuous improvement in the steelmaking industry. Through the strategic application of advanced V-Max™ Burners, DuraForge™ copper boxes, and sump panel technology, the customer has been able to dramatically enhance their EAF performance, reduce their environmental footprint, and improve overall operational efficiency.
Berry Metal’s commitment to innovation and customer satisfaction continues to drive successful outcomes for steel producers across the globe. As the partnership progresses, our team will continue to provide cutting-edge solutions that help customers optimize their EAF operations and achieve their goals for both productivity and sustainability.
If you’re looking to enhance the performance of your Electric Arc Furnace and achieve similar success, reach out to Berry Metal today. Our team of experts is ready to work with you to develop customized solutions tailored to your specific operational needs, driving greater efficiency, productivity, and sustainability in your steelmaking processes.