Which task was to be solved:
Project: Furnace 3 Relining 2023
Elkem Iceland had put out a Tender for total relining of Furnace 3. Relining of a Submerged Arc Furnace is a critical project that requires careful planning, precision, and the use of specialized materials and techniques. A Submerged Arc Furnace, often employed in the production of ferroalloys, metals, and other industrial applications, operates at extreme temperatures, subjecting its lining to intense wear and thermal cycling. Over time, the lining, usually made of refractory materials, degrades due to the high heat and chemical reactions within the furnace. When the furnace lining becomes compromised, it must be replaced to maintain the furnace's efficiency, safety, and longevity. Furnace 3 at Elkem Iceland is one of the biggest Submerged Arc Furnace in Europe and consists of over 500 Mt of refractory and Carbon paste.
How we solved the task:
Once it was clear that Eldfast won the Tender, planning started.
Eldfast is ISO certified for Installation and delivery of refractory materials. The certification is based on our delivery concept, which ensures good planning and implementation of this type of project:
- Engineering and planning: Inspection, reports, HSE-/quality-/resource-/progress plans.
- Work Execution: Mobilization of manpower and equipment, demolition, installation and daily reports.
- Reporting & Evaluation: Demobilization of manpower and equipment, documentation and evaluation.
The relining of Furnace 3 was a highly successful project, executed with meticulous planning, professionalism, and a strong commitment to safety, in great collaboration with Elkem Iceland. Delivered on time, within budget, and without any incidents, the project showcased exceptional financial and project management skills from all involved teams. The project team was composed of highly skilled professionals with extensive experience in furnace relining.
Adherence to safety standards and industry regulations ensured a zero-accident outcome, demonstrating the effectiveness of the safety management system and the vigilance of the team. The project also followed 5S principles (Sort, Set in Order, Shine, Standardize, Sustain), creating an organized, clean, and efficient work environment that not only enhanced safety but also minimized risks. The project required seamless coordination between multiple contractors working on different tasks.
Elkem Iceland played a key role in overseeing operations, holding coordination meetings every 12 hours to ensure smooth collaboration. Eldfast also conducted their own shift-specific safety meetings every 12 hours with the bricklayers. This clear communication and effective scheduling prevented disruptions and ensured all activities proceeded without delay.
At the core of the project’s success was a strong safety culture, with thorough risk assessments and a consistent focus on safety throughout every phase. This approach not only resulted in the project being completed on time, within budget, and to the highest quality standards, but also reinforced the importance of collaboration and safety in achieving outstanding outcomes.