Put simply, burn-loss is the undesirable loss of materials during remelting due to the alloy interacting with either the furnace wall or refining agent. While the flame furnaces used at Shanghai can theoretically produce burn-loss rates as low as 1.5–2 percent, in 2014 some 4.5 percent of material was being lost.
Ge Sun says to address the problem, a multidisciplinary team was assembled with staff from areas that included maintenance, projects, production, processes, and planning. The team studied every aspect of the burn-loss problem for a year.
“In the end, we found that several factors can influence burn-loss, including the type of furnace used, the type of raw material used and the remelting process, and how efficiently the furnace is used,” says Ge Sun.