A methodology for blast furnace hearth inner profile analysis

The wear of a blast furnace hearth and the hearth inner profile are highly dependent on the liquid iron flow pattern, refractory temperatures, and temperature distributions at the hot face. In this paper, the detailed methodology is presented along with the examples of hearth inner profile predictions. A new methodology along with new algorithms is proposed to calculate the hearth erosion and its inner profile. The methodology is to estimate the hearth primary inner profile based on 1D heat transfer and to compute the hot-face temperature using the 3D CFD hearth model according to the 1D preestimated and reestimated profiles. After the hot-face temperatures are converged, the hot-face positions are refined by a new algorithm, which is based on the difference between the calculated and measured results, for the 3D computational fluid dynamics (CFD) hearth model further computations, until the calculated temperatures well agree with those measured by the thermocouples.