Elkem Iceland is located in Hvalfjörður in West Iceland, about 40 kilometers from the capital Reykjavik. They are a part of a strong international entity, Elkem ASA, which is one of the world's leading manufacturers of silicon products. Their vision is to ensure a solid future for their plant with constant growth and innovations both in the service and product they provide for their customers. The core product at Elkem Iceland is ferrosilicon, which is one of the elementary raw materials for the steel industry. FeSi is either used for refining of steel or as an ingredient to reach predetermined qualities. Elkem Iceland has always produced standard FeSi, but in recent years, the plant has expanded its portfolio of specialty FeSi to meet increased market demand for such products.

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.

Statement from the customer:

"In late 2023 Elkem Iceland was working on relining on one of its largest furnace, furnace 3. Eldfast came in as the lining installation contractor on that project and did an exemplary job. All communications, worksite interactions and leadership of the team leaders were excellent. The installation work was also done to a very high standard in all aspects. Eldfast came in and emphasized safety heavily which is a prerequisite when working in heavy industry areas. 

The experience of working with Eldfast was and is very positive and will hopefully continue for years to come. Highly recommended."

- Vignir Bjarnason, Mainenance Manager and Project Manager