ABSTRACT
The new process development deals with the start-up of a new plant that had been technically unavailable. This chapter provides the process example that illustrates that even brand new and state-of-the-art process that have no specified operating controls can be advanced with the problem-solving techniques. A completely new process was created to produce quality briquettes for use within a cast iron melting facility. The new method was designed to replace a hydraulic operation that was used to compress oil- and coolant-soaked machining chips of cast iron into a brick of acceptable form that could be inserted into a cupola for melting. To overcome the environmental problem of fine dust polluting the atmosphere, a completely new briquette manufacturing method was designed to process the raw chip material. The chips continued to be fed into the elevator and into the furnace for a few minutes even though there was no escape path because of the jam-up.
