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<p>Refractory erosion in blast furnace (BF) hearths critically limits operational lifespan. This paper uses numerical simulation to model high-temperature molten iron flow in the hearth, focusing on three refractory masonry structures’ effect on heat transfer, thermal stress, and erosion resistance. Results show that heat transfer method requires a conductivity of at least 30 W/(m·K) to form a protective solidified iron layer; however, exceeding this threshold increases heat loss and shifts peak thermal stress toward the taphole, risking fracture. Heat isolation method’s low-conductivity ceramic cups retain heat but prevent protective layer formation, causing stress concentrations (&gt; 100 MPa) at the bottom corner (“elephant’s foot” erosion). By contrast, the heat avoidance and cooling intensification method employs a graded structure to stabilize a solidified layer, minimize heat loss, and reduce stress while cutting high-cost refractory usage. This work provides actionable insights for optimizing BF hearth design through balanced thermal management and cost efficiency.</p>

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Three-dimensional numerical simulation analyses for heat transfer and thermal stress in blast furnace hearth lining with different refractory masonry methods

  • 期刊论文

  • 发表日期：

    2025年8月1日

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  • Jincheng Wang,
  • Kunyu Ma,
  • Zhifang Wei,
  • Qinxu Cai,
  • Xianyou Huang,
  • Shuxing Qiu,
  • Liangying Wen,
  • Shengfu Zhang

摘要

Refractory erosion in blast furnace (BF) hearths critically limits operational lifespan. This paper uses numerical simulation to model high-temperature molten iron flow in the hearth, focusing on three refractory masonry structures’ effect on heat transfer, thermal stress, and erosion resistance. Results show that heat transfer method requires a conductivity of at least 30 W/(m·K) to form a protective solidified iron layer; however, exceeding this threshold increases heat loss and shifts peak thermal stress toward the taphole, risking fracture. Heat isolation method’s low-conductivity ceramic cups retain heat but prevent protective layer formation, causing stress concentrations (> 100 MPa) at the bottom corner (“elephant’s foot” erosion). By contrast, the heat avoidance and cooling intensification method employs a graded structure to stabilize a solidified layer, minimize heat loss, and reduce stress while cutting high-cost refractory usage. This work provides actionable insights for optimizing BF hearth design through balanced thermal management and cost efficiency.