Modernising Obsolete ESP Control Systems for a Leading Brazilian Steel Producer
25th June 2026 | Castlet
Sector: Steel
A major steel producer in Brazil was experiencing significant operational issues with its existing electrostatic precipitator (ESP) power systems. Working in partnership with our Brazilian agent, Klaus Essen, Castlet provided a long-term solution by upgrading obsolete equipment.
THE CHALLENGE
The plant was operating legacy three-phase equipment originally installed in the early 2000s by a European supplier. The equipment had become obsolete, with no spare parts available, resulting in repeated faults and unreliable operation.
Several fields across the plant were performing poorly, with low and erratic mA levels adversely affecting ESP efficiency and increasing the risk of unplanned downtime
The existing installed equipment was not manufactured by Castlet, and the documentation available at the enquiry stage was both incomplete and, in some cases, conflicting.
“The client was extremely happy with the end result; the ESPs are now operating efficiently, daily faults have been removed, and the risk of downtime has been greatly reduced.”
Ian Fox, Industrial Sales Manager at Castlet
Our Solution
Undertaking a comprehensive site inspection
To fully understand the site’s requirements and ensure compatibility with the existing infrastructure, Castlet conducted a detailed site survey alongside our Brazilian agent, Klaus Essen.
During the visit, our engineers carried out a comprehensive inspection of the existing control cubicles, transformer rectifiers and communication systems. This thorough assessment enabled Castlet to accurately identify the challenges being experienced by the client and develop a tailored replacement solution.
The refurbishment and re-tanking process
Based on the findings, Castlet proposed the supply of new three-phase transformer rectifiers and control cubicles, specifically engineered to integrate seamlessly with the existing ESPs and plant infrastructure while minimising disruption during installation.
Following order placement, Castlet undertook detailed engineering, manufacturing, factory testing, delivery and commissioning activities.
The scope of supply included:
Reducing risk of downtime and improving system reliability
By carrying out a detailed on-site survey and working closely with the client throughout the project, Castlet was able to develop a solution fully compatible with the existing plant infrastructure whilst ensuring minimal disruption to operations.
The complete project, from initial order through to successful commissioning on site in Brazil across two ESPs, was delivered within a 16-month timeframe.
The Outcome
The client was extremely satisfied with the outcome:
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