250T/50T+10T EAF Charging Crane for Emirates Steel Industries
A custom-engineered solution for ESI, incorporating advanced maintenance-friendly technologies such as anti-crabbing.
The Client
Client Name: Emirates Steel Industries
Sector: Steel billets and coils, rebar, and heavy sections
Location: Musaffah, Abu Dhabi, UAE
Scale: 3.6 MTPA
The Challenge
Problem Statement:
The client required a new EAF Charging Crane to handle increased production capacity at their existing plant.
Key Requirements:
- High load capacity
- Continuous duty cycle
- Redundancy for safety
- Precise control in a hostile environment
Core Issue:
Uneven long-travel rail tracks caused by wear and tear were leading to excessive wheel wear and structural stress on the crane due to skewing. This resulted in increased maintenance costs and unplanned downtime.
Client Requirement:
A system capable of automatically reducing the crane’s long-travel speed while traversing uneven rail sections.
Our Solution
Anti-Crabbing System:
Sensors were installed on both the rail and the crane. When the long-travel wheels pass over these sensors, the anti-crabbing system is activated, automatically slowing the crane’s movement.
Implementation
Process:
The anti-crabbing system was collaboratively engineered by Anupam and Siemens, combining domain expertise with advanced automation capabilities. The solution underwent detailed design and prototyping, followed by manufacturing at Siemens’ facilities in compliance with stringent quality standards. Final assembly, installation, on-site commissioning, and trial runs were executed at Anupam’s works to validate performance.
Timeline:
The system was successfully delivered and commissioned within 12 months, meeting the project’s critical schedule requirements.
Certifications & Safety:
The design and implementation complied with ISO and FEM standards, ensuring global quality benchmarks and operational safety.
Performance Improvements:
- 20% faster ladle handling operations
- 30% reduction in downtime
- Extended crane life cycle due to reduced mechanical stress
Operational Benefits:
- Improved plant productivity
- Safer working environment
- Significant reduction in long-travel wheel wear, leading to lower maintenance costs
Key Takeaways / Summary
Highlights:
- Custom-engineered solution for extreme operating conditions
- Delivered within time and budget
- Measurable productivity and reliability gains for the client
Anupam successfully delivered a customized engineering solution for Emirates Steel Industries within the contractual timeframe, resulting in reduced plant downtime and lower maintenance costs.
