Due to electrical stoppage during ice storm an iron melting pot full of molted iron was shutdown; within hours the iron in the kettle solidified into a 9,000 lbs slug.  Fascast called Taylor to evaluate and devise a plan to solve the problem… remove the slug from the refractory lined kettle.

Problems/Solutions:

1. Accessing slug w/lifting equipment

The kettle was not reasonably accessible with mobile lifting equipment; the plant’s overhead crane
was just out of reach.
Efficient Solution: Install rigging gear, including 2- 5 ton chain falls to the overhead crane.

2. Breaking bond between slug and kettle’s refractory sidewall

Upon hardening, the metal slug (approximately 2.5’ in diameter by 4.5’ tall) bonded tightly to the refractory.
Team Solution: Air hammer/chip as much refractory as accessible from around the slug.

3. Rigging to slug

Existing Solution: Removal of refractory allowed attachment of nylon rigging gear to slug.

4. Lifting the slug:

The obvious solution is to lift from above w/ the chain falls; realizing capacity limits of the chain falls
and rigging meant we needed to supplement lifting muscle.
Team Solution: Apply additional force to the bottom of the slug. A small access hole in the bottom
of the kettle allowed the utilization of a 50 ton jacking system.

Comments from the Client:
“The critical part of this project was removing the slug without damaging the furnace and furnace coils.  The thing that impressed me the most was a solid game plan was put in place by Mr. Taylor and the next day that plan was implemented without a hitch. FasCast, Inc. was very pleased not only with the quick response but, the final results.  When you have a tough rigging and removal job call Taylor Crane & Rigging.”

Bill Travis President
FasCast, Inc.