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<p>Industrial metals, such as pig iron, are produced in blast furnaces within the steel industry. During the smelting process in a blast furnace, a hot blast of air, exceeding 1373&#xa0;K, flows through the blowpipe. The refractory lining of the blowpipe is prone to erosion and thermal cracking due to hostile operating conditions. Any unnoticed erosion of a refractory liner at an inaccessible site may lead to blowpipe rupture. In the present investigation, numerical computations were performed using computational fluid dynamics (CFD) analysis to investigate the thermal profiles of similar abnormal or defective situations at varying distances from the blowpipe tip, thereby aiding in the appropriate positioning of sensors on the blowpipe surface.&#xa0;The numerically computed temperature profile of the blowpipe surface under an ideal case, without any abnormalities, was validated with the online plant data obtained from fiber Bragg grating (FBG) sensors embedded on the blowpipe surface. Thus, the simulated thermal profiles obtained through CFD analysis will be beneficial in ascertaining the anomalous condition of the blowpipe that occurs due to erosion.</p>

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Numerical Analysis and Experimental Monitoring of Blast Furnace Blowpipe Surface Temperature Utilizing FBG Sensors

  • 期刊论文

  • 发表日期：

    2026年1月30日

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  • Y. Usha,
  • S. Tewary,
  • A. Ghosh,
  • C. Dutta,
  • Alok Kumar,
  • T. K. Das,
  • P. Biswas,
  • S. Bandyopadhyay,
  • R. S. Sundaram,
  • S. Balamurugan,
  • S. Palit Sagar

摘要

Industrial metals, such as pig iron, are produced in blast furnaces within the steel industry. During the smelting process in a blast furnace, a hot blast of air, exceeding 1373 K, flows through the blowpipe. The refractory lining of the blowpipe is prone to erosion and thermal cracking due to hostile operating conditions. Any unnoticed erosion of a refractory liner at an inaccessible site may lead to blowpipe rupture. In the present investigation, numerical computations were performed using computational fluid dynamics (CFD) analysis to investigate the thermal profiles of similar abnormal or defective situations at varying distances from the blowpipe tip, thereby aiding in the appropriate positioning of sensors on the blowpipe surface. The numerically computed temperature profile of the blowpipe surface under an ideal case, without any abnormalities, was validated with the online plant data obtained from fiber Bragg grating (FBG) sensors embedded on the blowpipe surface. Thus, the simulated thermal profiles obtained through CFD analysis will be beneficial in ascertaining the anomalous condition of the blowpipe that occurs due to erosion.