Showa Denko PFC-75 Project

Fluor is providing engineering, procurement, construction/construction management (EPCM) services for Showa Denko Carbon, Inc.'s premium graphite electrode manufacturing facility. Located in Ridgeville, SC, this facility is 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 this award. As a part of the Showa Denko K.K. Group, Showa Denko Carbon, Inc. combines 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 is to meet increasing demands for its products as well as comply with stricter environmental regulations. At completion of the PFC-75 Project, production capacity will 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 has the PFC-75 project faced 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 continues to provide EPCM services to this significant expansion project. Construction execution includes a mix of Fluor's self-perform as well as subcontract personnel. Construction has 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 incorporates new emissions reducing technology specifically developed for this project.

“Fluor has earned Showa Denko's trust by understanding the company's needs, achieving outstanding safety performance, offering innovative project solutions, and delivering a One Fluor execution approach,” said Juan G. Hernandez, president of Industrial Services. “Fluor values its long-term relationship with Showa Denko, a South Carolina neighbor, and was proud to serve as a true partner in achieving Showa Denko's business and project objectives.”

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Conclusion

Having had presence off and on at this site since the early 1990's, Fluor continues to enjoy a 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 90's are still part of the team today. The Fluor project team committed to building on this record of performance and meeting all client objectives.

The project also continues to execute with an outstanding safety record, having achieved over 1.6 million safe work hours. Construction continues 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.