ME Elecmetal’s Duluth, Minn., casting facility produces chromium-molybdenum steel and white iron wear parts for the mining industry. Parts range from 200 to 10,000 lbs. and are produced from a unique vacuum molding process. Among vacuum process metalcasting facilities, Duluth produces the world’s largest tonnage of abrasion resistant castings.
In late 2012, the Duluth plant expanded its capacity by installing a third electric arc furnace identical to the two existing furnaces. The furnace was installed to upgrade the foundry’s capacity from 130 to 160 tons/day, with the potential for higher output depending on market demand (Fig. 1). The furnace addition resulted in a more continuous process, producing a heat every 65 minutes improving upon the 90-minute cycle times for two furnaces.