Refractories have a major influence on the operating cost and bottom line of any
smelting plant. The initial refractory material cost is significant, but the “full life
value” including loss of production and unexpected failures can be more
significant. Achieving the best “whole of life value” requires a fully integrated
management system incorporating:
- A full understanding of operating conditions, operating modes, and upset
conditions
- Uncompromising refractory design
- Refractory materials selection appropriate for operating conditions
- Specification of material properties and quality control requirements
- Quality installation and dry-out practices
- Maintenance monitoring during operation
- Development of a maintenance-management strategy, which is integrated
with mechanical maintenance and plant availability requirements.
Hatch recognizes that we must focus on key areas to achieve the best refractory
value. Only with close cooperation between client operating personnel, Hatch
process experts, and the Hatch Refractory Technology Group can superior
results be achieved. We have expanded our world-class Centre of Excellence
with a Refractory Practice Group to assist with refractory-specific needs across
the entire smelting process from bake furnaces, ladles, reduction cells to
aluminum holding furnaces.
Our group of refractory experts are experienced in all stages of refractory design
and commissioning including:
- Failure analysis – ladles, induction furnaces, casthouse furnaces and
reduction cells
- Condition assessments
- Build-quality audits and construction supervision
- Materials selection – launders, furnaces and consumables
- Prequalification of materials suppliers and installation contractors
- Refractory training
Other services include the evaluation and rebuild of casthouse furnaces
including condition assessment, project management, contractor selection,
specifications, manufacturing and installation quality control, and ongoing
operational support.
Hatch has provided services on numerous carbon-bake furnace rebuilds, which
included design, materials selection, procurement, installation and quality
control. We have developed strategies and recommendations to improve
refractory maintenance practices and the overall condition of carbon anodebaking
furnaces while optimizing carbon-bake furnace rebuilds to minimize loss
of production anodes.
