Innovative Integration & Industrial Impetus

In an era where environmental and safety concerns dominate industrial priorities, SMS group’s new partnership with The Systems Group ushers in a transformative chapter for steel production. The alliance focuses on incorporating Spray-Cooled® technology, a pioneering cooling system originally developed in the 1980s and now patented and refined by The Systems Group. This technology is designed to replace conventional tubular cooling methods, which involve high-pressure water systems that pose significant risks of leaks, leading to dangerous operational incidents and costly downtime. By embedding Spray-Cooled® into its electric arc furnace and secondary metallurgy plant solutions, SMS group is advancing safer, more efficient, and greener steelmaking processes across its global client base.

Cooling Creativity & Cathartic Carbon Curtailment

Spray-Cooled® technology operates at atmospheric pressure, a distinctive feature that fundamentally reduces the risk of catastrophic water leaks in melt shops. This attribute alone addresses a major occupational hazard in steel plants, where high-pressure leaks can cause explosions, fires, or severe injuries to personnel. But beyond safety, the technology contributes significantly to sustainability goals. It achieves superior heat retention during steelmaking, which leads to improved energy efficiency and a consequent reduction in carbon dioxide emissions. In the context of the steel industry's urgent drive to lower its carbon footprint, innovations like Spray-Cooled® present dual benefits: safeguarding workers and facilitating the decarbonization of steel production.

Structural Safety & Seamless System Synergy

Traditional tubular cooling systems involve pressurized water flowing through pipes that cool furnace roofs, hoods, and sidewalls. These systems require constant monitoring and maintenance to prevent leaks, which are notoriously difficult to detect and repair. Spray-Cooled® replaces these pipes with a network of nozzles that spray water droplets directly onto the furnace surface at atmospheric pressure. This design simplifies maintenance, reduces mechanical failure points, and adapts flexibly to different furnace shapes and sizes. The system’s modularity means steel producers can retrofit existing furnaces or integrate Spray-Cooled® in new plants with minimal disruption, optimizing uptime and extending equipment lifespan, key factors for profitability and operational continuity.

Leadership Luminaries & Legacy of Reliability

Senior executives from both SMS group and The Systems Group highlight the strategic importance of this partnership. Andrea Lanari, Vice President Metallurgy at SMS group, stressed the company’s dedication to pushing the boundaries of performance while elevating workplace safety and environmental responsibility. “Our collaboration with The Systems Group enables us to provide customers with a technology that has been proven over decades in the field,” Lanari stated. Lee Morgan, CEO and owner of The Systems Group, echoed this sentiment by pointing to the history of successful joint installations. He noted, “Our combined experience ensures that steelmakers receive solutions that not only maximize uptime but also create safer environments for their workforce, a top priority in modern steelmaking.”

Environmental Excellence & Emission Efficiency

Steel production is among the most carbon-intensive industries globally, contributing approximately 7 to 9 % of anthropogenic CO2 emissions. Cooling technologies that improve thermal efficiency directly influence emissions by reducing the energy required per metric ton of steel produced. Spray-Cooled® technology, by improving heat retention and reducing the need for additional energy input, supports these decarbonization efforts. Furthermore, its capacity to operate efficiently regardless of furnace size or operating conditions helps steelmakers meet increasingly stringent regulatory frameworks and international climate commitments. This environmental alignment positions SMS group and The Systems Group as forward-thinking players in the global steel sustainability movement.

Global Growth & Geographic Gravitas

With SMS group’s expansive global reach spanning Europe, Asia, the Americas, and Africa, and The Systems Group’s specialized expertise in cooling technology, the partnership is poised to accelerate adoption of Spray-Cooled® systems across diverse markets. Emerging steel producers in Asia and Latin America, who face growing demand for sustainable and safe production methods, will particularly benefit. Additionally, established steel hubs in Europe and North America can upgrade existing facilities to enhance safety and reduce emissions. This global distribution network combined with robust after-sales support services ensures customers receive tailored, end-to-end solutions that maximize operational efficiency and environmental compliance.

Operational Optimization & Outstanding Outcomes

The integration of Spray-Cooled® technology into SMS group’s offerings goes beyond simple equipment supply. The partnership brings a comprehensive engineering, project management, and technical support package. This end-to-end service includes feasibility assessments, custom design adaptations, installation supervision, and performance monitoring. Steelmakers enjoy increased furnace availability as cooling-related shutdowns decrease dramatically. The Spray-Cooled® system’s field-tested durability means fewer emergency repairs and lower total cost of ownership. By addressing critical pain points such as water leaks, thermal inefficiency, and maintenance burdens, the partnership sets new industry benchmarks for reliability and productivity.

Workforce Welfare & Win-Win Wellbeing

Occupational health and safety in steel plants is a pressing concern given the harsh and hazardous environment. High-pressure water leaks in conventional cooling systems rank among the top causes of workplace accidents, sometimes resulting in severe injuries or fatalities. Spray-Cooled® technology eliminates this risk by operating at atmospheric pressure, protecting workers from sudden and dangerous water bursts. This improvement enhances worker morale and productivity by fostering a safer workplace. Moreover, by reducing emergency downtime and unplanned maintenance, the system indirectly supports job security and operational stability, underpinning a holistic approach to industrial sustainability that values both human and environmental wellbeing.

Key Takeaways

• SMS group partners with The Systems Group to integrate Spray-Cooled® atmospheric cooling technology into electric arc furnace and secondary metallurgy solutions

• Spray-Cooled® technology eradicates high-pressure leak risks, enhances heat retention, reduces emissions, and simplifies maintenance, boosting uptime and safety

• The collaboration leverages decades of field experience to offer steelmakers worldwide safer, more sustainable, and efficient steel production capabilities