Chapter 5. Improving condition monitoring and maintenance framework for refractory linings in induction melting furnaces through continuous improvement methods
Keywords:
Induction crucible melting, refractory wear mechanisms, furnace lining durability, 3D laser scanning systems, automated condition monitoring, continuous improvement methodology, digital profiling technologies, TRIZ methodology, morphological analysis, method of control questions, method of focal objects, theory of inventive problem solving, functional-value analysis, slag formation optimization, crucible geometry adjustment, cooling regime improvementSynopsis
The service life and reliability of refractory linings in coreless induction crucible furnaces are essential factors influencing the efficiency, safety, and cost-effectiveness of metallurgical melting processes. Premature wear of linings, caused by the combined effects of slag composition, molten metal temperature, crucible geometry, electromagnetic stirring intensity, and cooling conditions, inevitably leads to increased maintenance frequency, unplanned production downtime, and higher operational costs. In the context of the global steel industry’s decarbonisation strategy and the growing demand for resource-efficient technologies, the issue of extending refractory lining durability in induction melting units gains particular relevance. This study presents an improvement of the lining condition monitoring and maintenance decision-making system through the integration of a continuous improvement methodology and heuristic engineering tools, including TRIZ, morphological analysis, the method of control questions, the method of focal objects, the theory of inventive problem solving, and functional–value analysis. The research incorporates both a review of existing industrial practices and an experimental evaluation of innovative technical solutions. A comparative evaluation of monitoring technologies was carried out, with the criteria including measurement accuracy, implementation complexity, cost, and adaptability to harsh metallurgical environments. This assessment resulted in the selection of laser-based 3D profilometry as the most appropriate solution for high-precision wear assessment and digital surface modelling, providing a reliable basis for predictive maintenance planning. The proposed approach combines technical and organisational measures, including optimisation of slag formation processes, adjustment of crucible geometry to reduce thermomechanical stresses, improvement of cooling regimes, and systematic wear tracking supported by digital data analysis. An industrial case study involving EGES-type furnaces at Zaporizhzhia Foundry and Mechanical Plant confirmed the applicability and efficiency of the developed framework under real production conditions, ensuring timely maintenance planning, reducing the risk of emergency lining failure, lowering specific energy consumption, and supporting stable quality of the produced steel. The findings demonstrate the potential of combining continuous improvement principles with modern monitoring technologies to create an integrated refractory lining management strategy that enhances durability, minimises environmental footprint, and strengthens the competitiveness of electrometallurgical production.
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Povazhnyi, O., Kukhar, V., Koyfman, O., Malii, K., & Pashynskyi, V. (2025). Chapter 5. Improving condition monitoring and maintenance framework for refractory linings in induction melting furnaces through continuous improvement methods. In P. Lezhniuk, V. Komar, V. Lysyi, Y. Malohulko, Netrebskyі V., O. Sikorska, V. Samsonkin, V. Druz, & O. Yurchenko, In press. PROCESSES AND CONTROL SYSTEMS: SYNTHESIS, MODELING, OPTIMIZATION. Kharkiv: TECHNOLOGY CENTER PC. Retrieved from https://monograph.com.ua/catalog/chapter/826/3722
