Permanent Control and Continuous Improvement of the Ferrosilicon Smelting Process

Abstract

The permanent control and continuous improvement of the ferrosilicon smelting process in the submerged-arc furnace is the primary task of the technological services and process management. This has a significant impact on the economic performance and competitiveness of the plant. This requires a precise definition and specification of all input and output components that affect the process technical and economic indicators. This procedure should be based on the identification of appropriately grouped components under the popular 6M principle (Man, Machine, Material, Method, Measurement, Management) presented in the form of Ishikawa cause and effect diagram. It is also useful to improve the process by the method of "small steps" in which employees of all levels participate (Kaizen method). The basic tool for improvement is statistical process control (SPC). The task of the SPC is to monitor parameters that are important for the physicochemical process and production results. Periodic material and energy balances of the process at discreet time intervals are also very useful. This allows us to monitor and provide information about the course of important parameters of the technological process and to respond quickly to irregularities.