Assessing Refractory Degradation and Damage by Acousto Ultrasonic-Echo

Abstract

Cooling staves, copper blocks and cooling plates play a crucial role in metallurgical vessels by efficiently dissipating excess heat from various furnace components to maintain the structural integrity of the vessel. Regulating the optimal thermal conditions within the furnace extends the refractory lining campaign life and contributes to enhancing operational efficiency. However, these cooling components are susceptible to corrosion and degradation in the hostile environment, and subsequently exacerbate the risk of water leaks, which then extend beyond immediate risks to include chilling of the furnace hearth, and explosions related refractory cracking and spalling, and damage of surrounding equipment. Assessing the extent and severity of the refractory damage caused by explosions poses a considerable challenge to traditional refractory monitoring techniques such as thermal monitoring. The accurate evaluation of the damage is hindered by the complex interplay of factors, making targeted maintenance efforts elusive. This paper explores the application of Acousto Ultrasonic-Echo (AU-E) as a non-destructive testing method to assess refractory condition. Case studies will be presented to illustrate the effectiveness of AU-E in assessing refractory degradation caused by thermal shocks and erosion during normal operational processes, as well as damages caused by explosions, offering valuable insights for optimal plans for maintenance, repair and reline.