Metals manufacturer Commercial Metals Company (CMC) has completed the successful start-up of a new Consteel system, designed and supplied by international furnace designer Tenova Core.
The Consteel system is one of several important processing systems at the new CMC micromill plant located in Mesa, in Arizona, in the US.
Consteel is a continuous steelmaking process, which preheats and feeds scrap and other raw materials directly into the electric arc furnace (EAF) through a patented conveying system through the EAF sidewall.
The successful team effort approach taken to implement the Consteel system in the CMC melt shop has already achieved excellent productivity and conversion cost results.
This project represents the seventh Consteel system in the US. There are 36 Consteel installations worldwide which are responsible for producing over 30-million tons of steel a year. The CMC facility produces reinforcing bar, while additional Consteel applications include flat, long and specialty steel products.
Meanwhile, the company has also established a new division, Tenova Re Energy, which specialises in heat recovery and energy efficiency for industrial furnaces.
Located in Düsseldorf, Germany, Tenova Re Energy has an engineering team with experience in steam generation heat recovery projects and has successfully managed several heat recovery projects for walking beam furnaces and EAFs, especially in the German market.
The efficient use of resources is an integral part of Tenova’s mission, which is energy efficiency, reduction of environmental impacts and higher product quality.
“The time was right to create a company only dedicated to heat recovery. [Energy input of] 25% to 40% in industrial furnaces is lost in waste gas and cooling water,” explains Tenova Re Energy CEO Ralf Granderath.
He explains that the heat recovery systems that the company has installed in Germany’s leading steel industries have already proven to regenerate energy from waste gases and have the capability to reduce the environmental impact of these industries.
Tenova Re Energy is deeply integrated in the global Tenova metal-making business area, where environment-friendly combustion techniques and hot recovery solutions are at the forefront of Tenova’s approach to the world energy scenario.
Tenova Re Energy technology is suitable for Tenova Pyromet submerged arc furnaces, Tenova hydroxylysine furnaces and direct reduced iron furnaces, Tenova Consteel and EAFs as well as walking beam furnaces.
“This technology is another milestone to emphasise Tenova’s role as technology leader for the metal and nonferrous industries,” says shareholder representative of Tenova Re Energy Mauro Bianchi Ferri.
He says the opportunity offers signifi- cantly lower operating costs through heat recovery as an integrated part of the company’s furnaces and it brings another competitive advantage to best serve its customers.