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Many technical papers focus on the “What” of new metallurgical furnace technology, i.e. What technologies to use and why. This paper instead concentrates on the “How”: How to successfully execute furnace rebuild/upgrade projects to achieve the expected benefits, and without overrunning the capital budget and/or time schedule. There is some commonality between the success factors for executing furnace rebuild projects and those for projects generally, i.e. safety is paramount. However, these rebuild projects have additional constraints, such as minimum shutdown schedule to avoid excessive lost production, key equipment only available from overseas vendors with long lead times, and the need for specialist skills such as furnace demolition contractors, refractory installers, and heat-up specialists. A furnace is rebuilt/upgraded typically only once every 5 or 10 years, and in that time owners tend to lose some of the institutional lessons learned from their previous furnace rebuilds. Based on our delivering multiple furnace rebuilds for clients each year, we have codified in this paper key success factors. Concepts discussed include first defining the “Why” to derive the scope; project phasing; front end engineering design (FEED); quantitative risk assessment; construction sequence (4D) simulation; pros & cons of various contracting strategies; modularization and design for construction; use of third-party specialist contractors and experts, etc. Examples discussed include the rebuild/upgrade of:

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Project Implementation Best Practices for Metallurgical Furnace Rebuilds and Upgrades

  • 会议论文

  • 发表日期：

    2025年

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  • Nils Voermann,
  • Bharat Kargutkar,
  • Anastasiya Mitsui,
  • Andrew Munsch,
  • Glenn Stevens,
  • Frank Stober,
  • Simon Nitschke,
  • Rob Sullivan,
  • Keith Joiner

摘要

Many technical papers focus on the “What” of new metallurgical furnace technology, i.e. What technologies to use and why. This paper instead concentrates on the “How”: How to successfully execute furnace rebuild/upgrade projects to achieve the expected benefits, and without overrunning the capital budget and/or time schedule. There is some commonality between the success factors for executing furnace rebuild projects and those for projects generally, i.e. safety is paramount. However, these rebuild projects have additional constraints, such as minimum shutdown schedule to avoid excessive lost production, key equipment only available from overseas vendors with long lead times, and the need for specialist skills such as furnace demolition contractors, refractory installers, and heat-up specialists. A furnace is rebuilt/upgraded typically only once every 5 or 10 years, and in that time owners tend to lose some of the institutional lessons learned from their previous furnace rebuilds. Based on our delivering multiple furnace rebuilds for clients each year, we have codified in this paper key success factors. Concepts discussed include first defining the “Why” to derive the scope; project phasing; front end engineering design (FEED); quantitative risk assessment; construction sequence (4D) simulation; pros & cons of various contracting strategies; modularization and design for construction; use of third-party specialist contractors and experts, etc. Examples discussed include the rebuild/upgrade of: