Detect refractory wear early in blast furnace stave cooling

Blast furnace copper staves protect the furnace shell and enhance wear resistance, but as the refractory lining erodes, more heat reaches the stave and its temperature rises. Temperature is one of the earliest indirect indicators of furnace condition during operation. iTHERM CableLine TSC310 cable probe, combined with the iTEMP TMT72 temperature transmitter, delivers robust, continuous stave temperature measurement under harsh conditions, helping operators detect leaks, blocked channels and refractory wear early, and avoid overheating, stave damage and hydrogen attack.

Continuous stave temperature monitoring turns an otherwise invisible furnace condition into an early-warning system.

Cooling system protection:

• Water leaks  
• Blocked pipe  
• Insufficient water flow 

Stave surface protection:

• Copper stave erosion

Blast furnace copper staves are a cooling solution designed to enhance wear resistance and prevent shell deformation. As the refractory lining wears away, more heat reaches the stave. Because the inside of a running furnace cannot be inspected directly, a rising stave temperature is one of the most important indirect indicators of refractory wearing away or erosion, allowing operators to identify problem areas long before a breakdown occurs.

Reliably capturing this signal is demanding: sensors must withstand large temperature swings together with fluctuating cooling water pressure and inlet/outlet temperatures across different furnace zones (belly, bosh, cohesive zone, etc.).

Typical process conditions:

• Cooling water inlet temperature: 25-35 °C
• Cooling water outlet temperature: 35-60 °C
• Cooling water pressure: 33-45 bar
• Stave temperature (depending on location): 50-250 °C

To meet these demanding requirements, Endress+Hauser equips the cooling staves with iTHERM CableLine TSC310, an industrial TC cable probe with quick-disconnect plugs that simplify installation. In this application, the OEM or plant builder typically specifies that a thermocouple (TC) measuring principle should be used, which makes TSC310 is the standard choice here.

4–20 mA / HART output is the established communication standard in the Mining, Minerals & Metals industry, which is why iTEMP TMT72 is a good fit: it is a HART-compatible DIN-rail transmitter that converts the thermocouple signal and ensures reliable communication with the control system. In addition, the SmartBlue App lets operators visualize process values directly on a mobile device, without additional wiring.

Together, these components form a temperature monitoring system that enhances process efficiency, improves safety, and supports consistent operation of the furnace.