Optimizing Manufacturing in the Steel Industry: Steel Plant Upgrades
Optimizing manufacturing in the steel industry focuses on upgrading existing plants, installing new facilities, and improving energy efficiency.
Key strategies include process optimization, environmental performance enhancement, and decarbonization, all aimed at boosting productivity, reducing energy use, and minimizing emissions for more sustainable steel production, while ensuring cost-effectiveness and long-term operational reliability.
Our Approach
At PT Carbon Process Engineering, we provide comprehensive services to modernize, expand, and decarbonize steel production facilities. Our approach combines strategic planning, proven engineering expertise, and practical implementation — delivering reliable, energy-efficient, and environmentally responsible solutions.
Our Core Services
- Upgrading and Modernization of existing steel plants and core process units
- Project Management for installation of new facilities
- Engineering and Technical Documentation: process flow sheets, feasibility studies, tender documents
- Energy Efficiency & Decarbonization: EAF optimization, process electrification, use of renewable reducing agents, SCU (Smart Carbon Usage), and exhaust gas system upgrades
- Environmental Optimization: CFD simulations, emission reduction systems, filtration and capture technologies
- Productivity Maximization: electrode regulation systems, automation upgrades, tap-to-tap time reduction
- Consulting and Supervision throughout all project phases
Practical Results We Deliver
- Increased EAF heat size by up to 20%
- Reduced energy consumption by up to 12% (down to <405–415 kWh/t)
- Reduced electrode consumption by up to 25%
- Power-off time reduced by up to 20%
- Emissions captured and reduced by up to 90%
Key Measures Applied
- Split-shell furnace design and structural upgrades
- Advanced electrode control systems with dynamic automation
- Custom scrap baskets and foaming slag management
- Primary and secondary exhaust gas system redesign
- Installation of modern filtration units and spark catchers
