monitoring and control of refractory wear for intensive operation of blast furnace

One of the main reasons for blast furnace reline is the loss of refractory lining, particularly in the hearth and taphole regions. Intense operation of the blast furnace can result in extensive refractory wear and deterioration, affecting the continuity of the operation and the furnace campaign life. Novo-Lipetsk (NLMK) and Hatch developed a systematic approach to monitor blast furnace hearth linings using Acousto Ultrasonic-Echo (AU-E), a non-destructive testing system. Continuous and periodic inspections revealed areas with accelerated refractory deterioration, formation of elephant foot, extent and speed of wear, as well as cracks and other anomalies. Improvements in coke quality, stave washing, and the addition of titania were recommended and implemented to prolong furnace life while maintaining operational intensity. This paper demonstrates how coordinated efforts between NLMK and Hatch led to an extension of the blast furnace campaign life.