Abstract

The refractory system in blast furnace hearth is exposed to harsh conditions and varying high temperatures. Such temperature fluctuation may generate undesirable refractory cracking and gap formation which could decrease the efficiency of hearth cooling system. Minimizing crack and gap formation and optimizing the bricking pattern, materials, and expansion allowances can improve the campaign life of the blast furnace hearth. This paper presents a novel assessment tool based on advanced finite element analysis for predicating refractory failure, mortar joint opening, and gap formation around ramming mixture in the hearth. Using this tool, locations of potential refractory system failures during blow-in and blow-down of the furnace can be identified and mitigated during design stage. This tool can also be utilized in order to understand the cause of hearth refractory wear in existing furnaces.