Screw Conveyors for Conveying EAF Dust at Cleveland Cliffs

General Description

Cleveland-Cliffs operates one of the largest integrated steel mills in the world near East Chicago, IN. During the production of molten iron, blast furnaces generate a fine, dense, and abrasive by-product known as blast furnace dust. This material is collected by air pollution control systems utilizing baghouses to capture and recycle air within the plant while preventing harmful emissions. The collected blast furnace dust is then conveyed to recycling or disposal facilities for further processing.

After years of service, the screw conveyors used to gather and transport blast furnace dust beneath the baghouses required replacement. Due to tight space constraints, the conveyors were originally designed with a special housing configuration to allow access for maintenance. With an upcoming scheduled shutdown, Cleveland-Cliffs needed fast delivery and reliable engineering support. Leveraging over 50 years of experience, KWS provided a timely, high-quality solution that met every operational and installation requirement.

Cleveland Cliffs Operates a Steel Mill in East Chicago, IN

Design Parameters

Product Type: Blast Furnace Dust
Material Density: 90 to 110 Lbs. per Cubic Foot
Design Temperature: 200-Degrees F
Capacity: 1,250 Cubic Feet per Hour
Designed Duty: 24 Hours per Day, 7 Days per Week

KWS Advantages

Due to the abrasive nature of blast furnace dust, hanger bearings were avoided whenever possible. KWS designed and manufactured each screw on oversized pipe to minimize deflection, allowing each conveyor to use a single screw section—reducing maintenance and improving reliability.

The conveyors had to fit within a very confined area. KWS technical personnel performed a detailed site visit to obtain precise dimensional data, ensuring perfect fit-up with existing baghouse discharges and structural supports. KWS engineers provided comprehensive drawings and were onsite during installation to advise on best practices and support startup procedures, ensuring a seamless transition to the new system.

KWS Special Features

Screw conveyor troughs were offset to enable the single-piece screws to be replaced without disturbing bolted connections to the baghouse. Quick disconnect keys were installed on both ends of each screw, allowing for easy removal while keeping the shafts and trough end assemblies in place. Without these design enhancements, the entire screw conveyor would need to be lowered and disassembled for maintenance.

These thoughtful engineering features dramatically simplified maintenance, minimized downtime, and extended the service life of the equipment—key priorities for Cleveland-Cliffs’ continuous operation environment.

Testimonial

"KWS did an incredible job to make the shutdown. The contractors on both baghouses commented on how well made the KWS screw conveyors were and how straightforward the fit up was. We are looking forward to getting the hopper screws replaced next."

K. Martin, Plant Maintenance Manager – Cleveland-Cliffs