The new double ladle furnace, which will replace the existing ladle treatment stand that has been in operation since 2012, is expected to reduce the plant’s carbon footprint, improve temperature control, and increase operational flexibility. The system is planned to be commissioned in March 2028.
At the Calvert plant, Outokumpu melts up to 100% stainless steel scrap in an electric arc furnace (EAF) and then processes it in an argon oxygen decarburization (AOD) converter.
As part of the project, one of the two ladle treatment stands will be converted into a double ladle furnace. This will increase process flexibility by adding electric heating capacity after the AOD process. The new system will be installed using the plant’s existing layout and foundations.
Primetals Technologies’ supply scope includes a rotating gantry system integrated with a water-cooled ladle cover, an electrode conducting arm equipped with a patented high-current system, automatic argon injection equipment, a hydraulic system, the Melt Expert electrode control system, a power solution, and a Level 1 automation system.
The Melt Expert system developed by Primetals Technologies for the new ladle furnace will provide dynamic control of the melting process, improving process stability. The system will help address low yield and productivity issues while reducing energy consumption and supporting lower energy costs during the melting process.
Collaboration began with the plant commissioned in 2013
The cooperation between Outokumpu Stainless USA and Primetals Technologies dates back to the design and supply process of the stainless steel production facility in Calvert.
The plant, consisting of a 160-ton electric arc furnace, a 180-ton argon oxygen decarburization converter, two 180-ton refining units, and a single-strand slab continuous casting machine, was successfully commissioned and received final acceptance in 2013.
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