Through the project, the defense and energy forgings maker replaced the furnace gantry, electrode columns and current-carrying arms, cabling, automation and control systems, and upgraded the hydraulics and water cooling. 

"Logistically and physically, this has been an enormous undertaking, and we have removed over 150 metric tons of steel, mechanical components, hydraulics, refractory material and cabling in order to re-fit the furnace up to a much higher specification," said Gareth Barker, operations director. 

“With the exception of the main hearth and staging, we have essentially built a new furnace that will operate much faster, with less energy consumption and will be capable of producing even cleaner steels."

Planning for the project began seven months ago and required a seven-week outage to remove old components and install new ones. The company said the modifications are providing a 15% increase in the furnace’s efficiency. 

“In order for Sheffield Forgemasters to compete in an increasingly competitive and fluctuating global market, the one thing we need to achieve in partnership with our technical excellence is the ability to make efficiencies across the board,” Barker said.