Colakoglu Metalurji, based in Dilovasi, Turkey, has upgraded its electric arc furnace (EAF) in partnership with Primetals Technologies, introducing advanced technologies aimed at improving efficiency and operational reliability. The revamped furnace features an innovative tilting device designed to enhance movement precision and speed. Combined with an electromagnetic stirrer (EMS) system supplied by ABB, the upgrade places the company among the leaders in modern electric steelmaking.
The new system improves operational reliability, energy efficiency, and furnace accessibility while simplifying maintenance. The modernization reflects Colakoglu’s commitment to sustainable, high-productivity steelmaking by combining robust mechanical engineering with advanced automation and data-driven solutions.
The project presented significant engineering challenges, as new mechanical and hydraulic components had to be integrated into the existing EAF within a brownfield environment. Unlike greenfield installations, the upgrade required precise alignment of the new tilting mechanism, structural frame, and EMS system with the existing furnace shell, foundation, and plant infrastructure. All work, including dismantling, structural modifications, reinstallation, and commissioning, was completed within a tight four-week schedule.
Execution in the confined furnace bay further increased complexity, demanding precise interface management, accurate prefabrication, and efficient logistics. Ensuring safety, quality, and long-term reliability while completing all mechanical and hydraulic work on schedule was a key challenge.
To meet the demanding timeline, Primetals Technologies and Colakoglu implemented a detailed engineering and installation strategy. New assemblies were preassembled and aligned during fabrication using 3D models and custom engineering drawings, enabling faster on-site installation and minimizing adjustments during construction.
Through modular preassembly, optimized logistics, and careful scheduling, the project was completed on time. The upgraded EAF now delivers improved efficiency, maintainability, mechanical stability, and long-term reliability, setting a new benchmark for brownfield EAF modernization projects.
Colakoglu is a leading Turkish steel producer headquartered in Istanbul, with production facilities in Dilovasi, Kocaeli. The company produces slabs, billets, hot-rolled flat steel, and rebar. In 2023, it also began producing special grades of stainless steel. Its annual production capacity includes 3 mln tons of crude steel, 4.5 mln tons of HRC and 1 mln tons of rebar.
