Apr. 22, 2022 - PRCO America has their first of four presses installed at new manufacturing plant in Mayfield, Kentucky, USA. The plant will produce resin bonded Magnesia Carbon and Alumina Magnesia Carbon bricks for the steelmaking industry to be used in Steel Ladles, Electric Arc Furnaces and Basic Oxygen Furnaces.
Material flow in the plant has raw materials entering on the left (West) to be mixed in one of the three Eirich high intensity mixers; the brick presses will be in the center bay, ABB robots will unload the presses, load the bricks onto steel pallets to be tempered in the tempering ovens in the East Bay and will unload the oven and package the bricks for a highly automated productive process.
Mayfield plant is on schedule to start production in mid-June 2022 with first production capability to be the full range of steel ladle MgO-C brick for 6 inch, 7 inch, 8 inch and 9 inch semi-universal brick and Mini Keys.
Mayfield plant will use the highest purity MgO for raw material. It is over 98.4% MgO with zero detectable boron, zero detectable chlorine and a Lime: Silica ratio of over 3.5 :1.0. MgO-C bricks made of this MgO show zero deformation under load up to the maximum test limit of the test which is 3800 F (2100 C). This achieves a 10-30% improvement in reduction of wear rates in the most critical zones of the steelmaking vessels for longer service life and lowest refractory cost per ton of steel produced. This MgO is exclusively available only from PRCO mines and fusion plant.
The Mayfield plant will operate using green electricity generated by the Tennessee Valley Authority hydro electric system for lower Green House Gas emission which may help steelmakers reduce their GHG by lowering their Scope III emissions.
The photo below also shows the pouring of concrete for our second press. The second press will arrive this summer and expand our size capability to include bricks for the EAF and BOF later in 2022.
PRCO America is working with SRI to achieve ISO 9001:2015 in 2022.
PRCO America has their first shift hired and actively engaged with our plant engineers for commissioning and training on site.
PRCO America is hiring for second shift and for various support functions for Order Entry, Logistics, Cost Accounting,
PRCO America will be presenting a technical paper at the upcoming AISTech 2022 conference in Pittsburgh May 16-19, 2022 on the use of our new Mgo-C for making longer life EBT Tap Tubes for the EAF for lower cost, faster tap and cleaner steel.
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