How to Extend Blast Furnace Campaign Life

This presentation details a comprehensive strategy for achieving unprecedented furnace longevity by integrating operational taphole analytics with next-generation structural monitoring. It addresses the core challenge of hearth degradation, which is driven by fluid dynamics—such as uneven liquid levels—and structural stresses like chemical attacks and extreme thermal loads. The presentation is built upon "Twin Pillars": • Pillar 1 (Operational Optimization): Utilizes a 16-parameter dashboard to track critical metrics like drainage time (170–190 minutes) and taphole length (3,100–3,400mm) while standardizing casthouse disciplines like drill geometry and mud extrusion. • Pillar 2 (Structural Monitoring): Overcomes the "blind spots" of legacy 1D thermal modeling—such as thermal inertia and the "elephant foot" effect—by fusing Acousto-Ultrasonic Echo (AU-E) with 2D thermal mapping. The presentation concludes with the Hearth Stability Loop, showing how standardized operational execution directly protects the structural boundary to stabilize the protective skull and prevent refractory erosion.