ME Elecmetal’s Duluth Facility Furnace Upgrade
ME Elecmetal is a global leader in the design and manufacture of wear parts for the mining industry. With a focus on innovation and advanced technology, we supply high-performance mill lining and crushing products to customers both locally on the Iron Range and around the world.
We’ve been part of Minnesota for over 100 years, with our Duluth facility operating since 1978 and employing 135 dedicated team members. Sustainability is at the core of our operations:
We’re also committed to protecting our most valuable asset—our people. The Duluth facility is proudly celebrating 4 ½ years without a lost time accident.
ME Elecmetal is ISO 9001:2015 (Quality) and ISO 14001:2015 (Environmental) certified, reinforcing our dedication to excellence, safety, and sustainability.
To further improve sustainability and efficiency, ME Elecmetal’s Duluth Facility is upgrading its melting technology from Electric Arc Furnaces (EAF) to Coreless Induction Furnaces (CIF).
Two CIFs will replace the output of three existing EAFs, delivering significant environmental and operational benefits:
This $14.9 million upgrade project is supported by a $4.3 million grant from the Minnesota Pollution Control Agency (MPCA) through the Industrial Facility Air Toxic and Criteria Emission Reduction Grant program.
Together with our partners and community, ME Elecmetal continues to invest in sustainable technologies that advance efficiency, safety, and environmental stewardship.
| Phase | Timeline | Milestones | |
|---|---|---|---|
| Phase 1 | Through 1/2026 | Complete project engineering and obtain modified air permit (reflecting reduced emissions related to conversion to CIF technology) | |
| Phase 2 | 2/2026 - 10/2026 | Construction in melt shop to prepare for CIF A installation | |
| Phase 3 | 10/2026 - 2/2027 | Install and commission CIF-A | |
| Phase 4 | 10/2026 - 4/2027 | Construction in melt shop to prepare for CIF-B installation | |
| Phase 5 | 4/2027 - 6/2027 | Install and commission CIF-B |
| Question: | Answer: | ||
|---|---|---|---|
| Why is ME Elecmetal pursuing this upgrade? | We are pursuing this upgrade to reduce emissions, increase efficiency, and improve worker safety. The transition from electric arc furnaces to induction furnaces supports our commitment to environmental stewardship and operational excellence, while enhancing the foundry’s long-term sustainability. | ||
| When will construction begin? | Construction is scheduled to begin in Q1 2026. The first induction furnace is expected to be operational at the beginning of 2027, with the second furnace coming online mid-2027. | ||
| Will production continue during construction and installation? | Yes. Production will continue throughout the upgrade. The project has been carefully planned and phased to minimize disruptions and maintain customer deliveries while new systems are installed and commissioned. | ||
| What is the difference between EAF and CIF melting? | EAF melting uses powerful electric arcs formed between graphite electrodes and the metal charge; these arcs generate extremely high temperatures (up to ~3,500°C). CIF melting uses electromagnetic induction; an alternating current passes through a coil, creating a magnetic field which induces currents inside the metal, heating it internally. |
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| How old is CIF and EAF melting technology? | CIF technology was first patented in 1900, with continued modifications through present. EAF technology was successfully patented in 1889, with continued modifications through present. |
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| How does melting speed compare between current and new technology? | Our current Electric Arc Furnaces (EAFs) can melt approximately 15 tons of metal in about 3 to 3.5 hours. The new Coreless Induction Furnaces (CIFs) will dramatically increase melting efficiency, capable of melting 15 tons of metal every hour — a significant productivity improvement. | ||
| Will any changes be required to our incoming scrap materials as part of the conversion? | Most scrap used is either worn out mill liners, plate scrap, and railroad track and wheel materials (we recycle this steel into new castings). The main change will be requiring the material to be precut into smaller pieces. No automotive or painted scrap in allowed for our production. | ||
| Do we recycle metal from the Iron Range? | Approximately 95% of our furnace charge material is recycled metal; this includes both internal material (riser and gating), used mill liner and crusher parts from mines, used railroad track and wheel materials, used plate steel scrap, etc. No automotive scrap is used by the facility. | ||
| Is ME Elecmetal switching completely over to CIF melting / are they taking out all the EAF units? | Currently only one EAF is going to be removed. The remaining two will be maintained for use during the transition to CIF melting and then as back-ups. | ||
| Is the noise from CIF technology predicted to be less than from EAF technology? | The noise profile of CIF technology is different than EAF technology, so there will be some change. Due to the furnaces (both EAF and CIF) being inside the building, ME Elecmetal does not know the full extent the upgrade will make on the overall noise profile of the facility. | ||
| How deep will the excavation be for the new furnaces? | Excavation will reach depths of approximately 15 to 18 feet, with the finished foundation depth at around 10 feet. | ||
| Where are the CIF systems being manufactured? | Our new induction furnaces are manufactured by ABP, a global leader in foundry and melting technologies, headquartered in Germany. ABP’s systems are known for their precision, energy efficiency, and reliability. | ||
| What reduction in power consumption is expected from the conversion from EAF to CIF? | Following the upgrade, ME Elecmetal anticipates an approximate 7% reduction in overall power consumption. | ||
| What portion of the total investment will be allocated to labor? | While final figures are still being confirmed, ME Elecmetal estimates that 35–40% of the $14,940,000 total investment will be directed toward labor-related expenses. | ||
| Does ME Elecmetal provide the opportunity for tours / when will our next open house be? | ME Elecmetal typically hosts a Manufacturing Day event during the first Saturday of October where employees, their families, and the community can tour the facility. Manufacturing Day is tentatively scheduled for 10/3/2026, but details will be posted on our website closer to the event. |
| Name | Title | Phone | |
|---|---|---|---|
| Matt Christenson | Community Engagement | 218-213-9557 | duluthupgrade@meglobal.com |
| Benj TerLouw | Grant Coordinator | 218-213-9557 | duluthupgrade@meglobal.com |
| Justin Meller | Duluth Plant Manager | 218-213-9557 | duluthupgrade@meglobal.com |
| Event Name | Date | Location | Link |
|---|---|---|---|
| National Night Out | August 4,, 2026 6:00 PM |
TBD | |
| ME Elecmetal's Manufacturing Day Open House | October 3, 2026 10:00 AM-2:00 PM |
ME Elecmetal Duluth Foundry 200 E Carterett St. Duluth, MN 55808 |
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