Title

Operational Performance and Future Outlook of Spray-Cooled EAF Conversion at SDI Columbia City

Operational Performance and Future Outlook of Spray-Cooled EAF Conversion at SDI Columbia City

Authorship

HANSERT, PATRICK; FERENCZY, STEPHAN; TEW, KYLE; GROSS, CLAY; FERGUSON, SCOTT

HANSERT, PATRICK

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FERENCZY, STEPHAN

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TEW, KYLE

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GROSS, CLAY

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FERGUSON, SCOTT

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DOI

10.5151/2594-5300-42029

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Abstract

In 2016, SDI's Structural and Rail Division (SRD) in Columbia City, Indiana initiated a strategic upgrade to its electric arc furnace (EAF) operation. The facility transitioned from pressurized tubular water-cooled panels to a modern spray-cooled upper shell system. This enhancement aimed to address safety concerns, improve thermal performance, and lower maintenance demands. Over time, complementary technologies such as a spray-cooled roof, elbow, copper burner box, and the SYSTEMS Spray Safe Humidity Sensor were also introduced. This paper details the technical, economic, and operational benefits realized from these innovations.

IN 2016, SDI'S STRUCTURAL AND RAIL DIVISION (SRD) IN COLUMBIA CITY, INDIANA INITIATED A STRATEGIC UPGRADE TO ITS ELECTRIC ARC FURNACE (EAF) OPERATION. THE FACILITY TRANSITIONED FROM PRESSURIZED TUBULAR WATER-COOLED PANELS TO A MODERN SPRAY-COOLED UPPER SHELL SYSTEM. THIS ENHANCEMENT AIMED TO ADDRESS SAFETY CONCERNS, IMPROVE THERMAL PERFORMANCE, AND LOWER MAINTENANCE DEMANDS. OVER TIME, COMPLEMENTARY TECHNOLOGIES SUCH AS A SPRAY-COOLED ROOF, ELBOW, COPPER BURNER BOX, AND THE SYSTEMS SPRAY SAFE HUMIDITY SENSOR WERE ALSO INTRODUCED. THIS PAPER DETAILS THE TECHNICAL, ECONOMIC, AND OPERATIONAL BENEFITS REALIZED FROM THESE INNOVATIONS.

Keywords

Electric Arc Furnace, Spray-Cooled Shell, Maintenance Optimization, Energy Efficiency, Leak Detectio

Electric Arc Furnace, Spray-Cooled Shell, Maintenance Optimization, Energy Efficiency, Leak Detection