The advancement of metallurgical vessels, such as blast furnaces, shaft furnaces, and torpedo ladles, can be better controlled and expanded for a greater lifespan if the thickness of the refractory lining wear is known and predicted. In the past, various methods including radioactive tracers, infrared (IR) thermography, electromagnetic waves, ultrasonic tomography, and temperature field have been tested to determine the thickness of the refractory wall. However, for various reasons, these methods have failed to be effective. This paper presents a novel method-electromotive force (EMF)-for predicting the thickness of refractory lining wear in vessels, including a small-scale vessel in the laboratory, an industrial torpedo ladle, and in the two refining hearths of blast furnaces. The experimental results show that the magnitude of the EMF signal increases with a decrease in wall thickness. Prediction values of the refractory wall thickness are consistent with measured ones. The relative error of EMF measurement for the torpedo ladle is around 6.8%. The EMF measurement of blast furnace hearths is quite accurate, and the relative error is less than 11%.
Keywords: blast furnace monitoring; electromotive force; hearth campaign; refractory thickness; vessel campaign.