The Challenge

A leading steel producer in Virginia was experiencing persistent descaling issues on beam blanks during production. The previous descale header and nozzles struggled to remove mill scale effectively, especially in critical design areas. The main issues included:

• Insufficient impact in radius web sections: The complex curvature of beam blanks meant certain radius areas were not receiving enough water impact force to fully remove scale.
• Excessive descaling gaps: Poor spray coverage created “striping” and left untreated sections, resulting in inconsistent surface quality.
• Residual scale leading to build-up: The incomplete descaling left more oxide on the surface, accelerating build-up on the work rolls. This required more frequent work roll re-dressing, increasing downtime and maintenance costs.

The Lechler Solution: SCALEMASTER® HP Superior

Lechler, Inc. implemented its SCALEMASTER® HPS descale nozzles with a custom-engineered header configuration specifically tailored for the facility’s beam blank shape and production needs. The results were immediate and measurable:

• Proprietary header configuration for maximum impact in problem areas
  The SCALEMASTER® HPS system was designed to deliver optimized jet impingement exactly where it was needed most, particularly in the radius web sections where traditional nozzles underperformed. This ensured uniform scale removal even in hard-to-reach contours.
   
• Optimized flat fan overlap to eliminate striping
  By reengineering the spray pattern alignment, Lechler eliminated gaps and excessive overlap, producing a continuous descaling zone across the entire beam blank width. This precision targeting ensured a cleaner, more uniform finish without wasted water or energy.
   
• Significant improvement in downstream surface quality
  With a cleaner beam blank entering the beam mill, the facility saw a dramatic reduction in work roll wear. The need for re-dressing dropped considerably, saving both time and operating costs. Operators reported that beams were “very clean prior to fabrication,” enhancing overall process efficiency and product quality.
   
• Enhanced nozzle durability and protection
  Recognizing the heavy-duty demands of steel production, the SCALEMASTER® HPS system incorporated robust mechanical protection to safeguard nozzles from accidental beam blank collisions, reducing unexpected downtime and replacement costs.

Results

The steel producer reported consistently cleaner surfaces, reduced maintenance requirements, and improved process efficiency. The upgrade not only boosted product quality but also minimized operational disruptions, demonstrating the long-term value of precision-engineered descaling technology.