Key Spray-Cooled™ Projects

With our experienced team of Engineers and Designers, Systems Spray-Cooled can handle any sized project from a single piece of equipment conversion to an entire meltshop of equipment and off-gas ducting.  We have the facilities and experience to handle any project our customers need.

Some of our recent large scale projects include:

Spray-Cooled™ Capabilities Brochure

  • Complete meltshop equipment (sidewalls, roofs and elbows for a 26’-4” dia furnace) and off-gas ducting (approximately 180’ of 10’ dia duct including a 13’-4” x 19’-11” x 23’-10” tall panelized dropout chamber) for two identical furnaces at Steel Dynamics in Columbus, MS (formerly Severstal)
  • Sidewalls and roofs for two 24’-4” dia furnaces, including two 15’-4” x 15’-4” dropout chamber roofs, for Nucor-Yamato Steel in Blytheville, AR
  • Replacement 11’-7” x 14’-7” x 37’-9” tall panelized Consteel off-gas doghouse duct for Nucor Steel in Cofield, NC
  • Roofs and elbows for a 24’-7” dia. twin-shell furnace at Nucor Steel in Tuscaloosa, AL
  • Sidewalls and roofs for two 22’-4” dia. Furnaces at Nucor Steel in Crawfordsville, IN
  • Sidewalls and roofs with integrated elbows for a 26’-4” furnace for Big River Steel in Osceola, AR
  • Roofs and elbows for a 20-10” dia. furnace for Nucor Steel in Kankakee, IL

Cool Facts

Spray-Cooled™ Equipment
is SAFER
Operating at atmospheric pressure, SYSTEMS Spray-Cooled™ equipment minimizes the amount of water present during an upset event. Our patented technology eliminates the potential of high pressure, high volume water leaks… Just one less thing to worry about! Learn More »
Spray-Cooled™ MORE UPTIME, LESS DOWNTIME SYSTEMS Spray-Cooled™ equipment's lack of valves and hoses eliminates two sources for water leaks. Stainless steel components and the inherent scrubbing action of the spray cooling water virtually do away with scale build-up. And, because the system operates at atmospheric pressure, leaks can be repaired on-line, quickly and easily using our quick and easy welded patch. Learn More » Spray-Cooled™ Equipment LOWERS MAINTENANCE COSTS SYSTEMS Spray-Cooled™ equipment’s custom sized and located, multiple access ports provide free access to the spraying system and wet side hotface. This accessibility eliminates the need to work overhead, and the need to remove equipment off-line for routine inspections and repairs. Thin plate construction drastically reduces spare parts inventories and facilitates a long range, Re-build versus Replace cost reducing campaign. Learn More » Spray-Cooled™ Equipment ENHANCES FURNACE EFFICIENCY Utilizing our patented methods and products, SYSTEMS Spray-Cooled™ equipment exhibits excellent slag retention characteristics - even in extreme heat load areas. Acting as an available “free” insulator, the uniform slag coating improves energy and heat retention inside the furnace. Also, when fully outfitted with Spray-Cooled™ furnace components, additional scrap volume is available without modifications to the furnace superstructure or bottom shell, further reducing energy losses and costly shop logistics. Learn More » Spray-Cooled™ Equipment FACILITATES OPERATIONAL FLEXIBILITY SYSTEMS Spray-Cooled™ equipment is easily modified to meet the changing needs of a modern steel shop, such as the addition, removal, relocation, or modification of burners, slag tunnels, charge holes, inspection ports, process openings etc. without the need for costly new panels. Learn More » Spray-Cooled™ Equipment provides for a CLEANER ENVIRONMENT SYSTEMS Spray-Cooled™ equipment’s One-Piece design minimizes flame and fume emissions. This also reduces air infiltration and improves gas handling efficiency. Not only is your shop and operating environment cleaner, it’s COOLER too. Learn More » Spray-Cooled™ Equipment The Safer water-cooled Alternative Utilizing our patent protected technology, SYSTEMS Spray-Cooled™ equipment provides a more efficient use of available cooling water to protect your equipment in the most extreme heat load applications in a non-pressurized, gravity return system, thus eliminating the potential of high pressure, high volume water leaks. Learn More » Spray-Cooled™ Equipment Eliminates Panel-to-Panel Gaps Our one-piece construction means that SYSTEMS Spray-Cooled™ equipment has no panel gaps to allow air infiltration or exfiltration. Not only does this increase overall furnace efficiency but also helps to keep your workplace cleaner. Learn More » Spray-Cooled™ Equipment REBUILD versus REPLACE By the nature of its design and construction, SYSTEMS Spray-Cooled™ equipment has an indefinite life, with the thin, carbon steel, hot face being the only “wear” item in its construction. Upon reaching the cyclic life of the hot face, it is not necessary to replace the entire piece of equipment but simply rebuild the wear item and the Spray-Cooled™ component is as good as new. Learn More » Spray-Cooled™ Equipment MAXIMUM WORKABILITY Using thin wall, carbon steel plate for construction of SYSTEMS Spray-Cooled™ equipment structural, containment, and hot face elements provides for maximum on-site workability. Combined with the inherent atmospheric cooling system pressure, the thin wall construction facilitates quick “on-the-fly” repairs made from the cooled side for added Safety Precautions. Learn More » Spray-Cooled™ Equipment QUALITY CONSTRUCTION At the heart of SYSTEMS Spray-Cooled™ equipment, the Spray System is constructed for maximum longevity and minimum maintenance hassle. All of the spraying system piping is fabricated from stainless steel pipe to eliminate corrosion. Each spray system bar is coupled to the supply water header with quick connect couplers of locking, brass construction, and each nozzle is our own patented, Clog Resistant style brass nozzle. This Quality Approach to the materials of construction and our proprietary fabrication techniques combine to provide only the highest quality EAF equipment. Learn More » Spray-Cooled™ Equipment CLOG RESISTANT SPRAY NOZZLES Manufactured in brass, with removable and replaceable atomizing plates and nozzle tips, SYSTEMS Spray-Cooled™ patent protected Clog Resistant nozzles provide approximately 5x the bore of most other commercially available nozzles. This provides for minimal consideration to water treatment. Providing a full cone spray pattern at 30psi supply pressure, our standard nozzles are offered in both English and metric pipe threads, and are available in a wide range of flows. Learn More » Spray-Cooled™ Equipment ENERGY EFFICIENT With a more efficient (and Safer) water-cooling method, and a proprietary and patented Slag Retention system, SYSTEMS Spray-Cooled™ furnace components reflect and retain more heat in the furnace. This combined with the added benefits provided from our one-piece construction means a significant increase in operating energy efficiency. Learn More »