A stave cooling system is a key element in the blast furnace which protects the outer shell from heat by providing uniform cooling. Real-time condition assessment of staves is essential to understand the wear mechanism of staves. Inspection rod/waveguide of known length which is made of copper was inserted through the steel shell till the inner end of the stave where the waveguide is susceptible to reduce in length as stave erodes with time. FEM analysis was done to find the ultrasonic parameters and lab-scale trials were taken on artificial waveguides with different end conditions. Based on the results, an ultrasonic-based real-time thickness measurement system was developed to continuously measure the length of the inspection rod/waveguide which eventually represents the stave thickness. System was installed in the plant, the data was captured and shown for 60 days from the date of the installation with an accuracy of more than 98%.
Stamped charging of coal has become increasingly demanded in blast furnaces, as pulverized coal injection is more used. In the stamped charging process, the bulk density of the coal is the most important parameter, which affects the productivity and campaign life of the coke oven batteries. Hence, online measurement of coal bulk density is very crucial for increased productivity. In this paper, a novel methodology that exploits the relationship between coal bulk density and sidewall pressure is discussed. The relationship has been quantitatively established by lab-scale experiments. Also, the lab-scale experiment describes a unique methodology, which enables pressure sensor mounting on the actual stamping machine for the actual application. The obtained relationship can be used directly for determining the bulk density of the actual stamped charge coal cakes in coke plants.
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