Ladle Bottoms at Atlas Specialty Steels (Welland, ON) Continuous Improvement and Problem Solving

摘要

This example illustrates the successful application of standard problem-solving techniques to a refractory problem. Pareto analysis will point out those areas requiring attention. Optimization of an existing design will allow for some consistency and balance, but it ignores the larger picture, which is the proper selection and application of refractories. Without this step, the likelihood of fine-tuning the best lining is slim and the end results may be quite disappointing. The correct order of evaluation begins with the chemical compatibility of the available materials with the slag and steel-making process. Once incompatible refractories have been eliminated, the remaining choices should be examined for their physical characteristics. Identifying the primary wear mechanisms allows selection of refractories with the correct physical properties. This can be done by intuition or experience, but Pareto charts make it easier to grasp complex scenarios with multiple wear mechanisms. With all of the analysis complete, trials can begin and eventually an optimized design can be reached by zoning in quality and thickness with refractories best suited to the particular application. The reward for all of this effort is lowest possible cost, highest performance and availability, minimal waste, and a safe reliable vessel that provides predictable service.