Sustainability and cost-efficiency are no longer at odds. In today’s steel industry, doing what’s right for the environment increasingly means doing what’s right for your bottom line. At Lechler, Inc., we understand that manufacturers are under pressure to reduce energy consumption, minimize waste, and improve product quality while cutting costs. That’s why our spray solutions are engineered to optimize performance and resource efficiency across your operations.
Two of our most innovative solutions: The SCALEMASTER ECO+ for descaling and the Slabcooler ECO for slab cooling, which boosts this philosophy of sustainable performance. These products are helping mills across North America and beyond by cutting water and energy consumption, reducing maintenance needs, and boosting product yield.
SCALEMASTER ECO+: A Smarter Approach to Descaling
Traditional descaling systems often suffer from poor energy efficiency, excessive water use, and inconsistent surface quality. The SCALEMASTER ECO+ addresses all three of these issues through precision-engineered nozzles and optimized spray header design.
By delivering high-impact spray at closer standoff distances, ECO+ nozzles allow for:
- Improved scale removal
- Reduced water consumption
- Lower energy use due to less reheating or repeat processing
These performance advantages aren’t just theoretical; they’re proven in real-world installations.
Case Study: Descale Optimization at a U.S. Hot Mill
In May 2024, a Lechler sales engineer met with engineers at a hot strip mill in Ohio, to discuss persistent issues with slab descaling. The plant had been experiencing black striping marks on their slabs, especially after long furnace dwell times or when processing silicon steels.
Our simulation analysis revealed the culprit: a standoff distance over 12 inches, a legacy design from an older descaling system. We recommended reducing the standoff to between 4–6 inches, which the plant confirmed was feasible. This change allowed for a more effective scale removal while minimizing the risk of slab cobbles damaging the nozzles.
After months of collaboration, Lechler delivered custom-fabricated top and bottom descale headers with SCALEMASTER ECO+ nozzles in November 2024. Early 2025 feedback from the mill was encouraging:
- 20% preliminary improvement in slab surface quality
- No clogging issues with the long weld bases on ECO+ nozzles
- Nozzle plugs supplied for unused spray positions, improving system flexibility
The plant is now considering relocating descale header mounts to further optimize spray efficiency and is planning to integrate additional Lechler headers during their next major outage.
