Showa Denko PFC-75 Project
Client: Showa Denko Carbon, Inc.
Location: Ridgeville, SC, U.S.
Business Segment: Urban Solutions
Industry: Manufacturing
Executive Summary
Fluor provided engineering, procurement and construction/construction management (EPCM) services for Showa Denko Carbon, Inc.'s premium graphite electrode manufacturing facility. Located in Ridgeville, SC, this facility was the largest of its kind in the world, producing graphite electrodes for electric arc furnace steel production. This was the largest manufacturing expansion project for Fluor in the Southeastern United States at the time of the award. As a part of the Showa Denko K.K. Group, Showa Denko Carbon, Inc. combined the most modern, fully integrated, graphite plant in North America and the capabilities of a global organization with extensive expertise in carbon and graphite technologies.
Client's Challenge
The goal of the PFC-75 project was to meet increasing demands for its products as well as comply with stricter environmental regulations. At completion of the project, production capacity would increase from 45,000 MT/year to 75,000 MT/year allowing Showa Denko to meet increasing demand for its graphite electrodes and automotive friction materials.
Not only did the PFC-75 project face new, more rigorous environmental regulations, but surrounding wetlands limited the real estate for expansion.
Fluor's Solution
Fluor's local offices in Greenville and Charleston, South Carolina, as well as overseas support from the Manila, Philippines, office provided EPCM services to this significant expansion project. Construction execution included a mix of Fluor's self-perform as well as subcontract personnel. Construction peaked at approximately 500 employees, including approximately 275 Fluor craft workers and 23 management professionals. A Fluor subsidiary provided construction tools for the project while Fluor's Plant Engineering Services in Charleston, South Carolina, delivered local technical support.
Specialized preparation of furnace kilns before placement of the foundations accelerated the schedule by approximately 15 weeks. This expansion also incorporated new emissions reducing technology specifically developed for this project.
Conclusion
Having had a presence off and on at this site since the early 1990's, this project continued Fluor's long-standing business relationship and record of performance. In fact, multiple Fluor employees who were a part of previous expansions at this facility in the early days were still part of the team during the project. The Fluor project team committed to building on this record of performance and meeting all client objectives.
The project also executed with an outstanding safety record, achieving over 1.6 million safe work hours. Construction continued to be executed in the midst of a fully operational manufacturing facility with minimal outages and downtime. In 2016, the National Safety Council recognized the project with the Million Work Hours Award for exceptional safety performance.
Project Gallery
