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<p>The present work reports the development of an intelligent, automated system for accurate determination of critical cast house parameters in blast furnace operations, addressing the inherent limitations of manual and imprecise practices. The system integrates a sensing device mechanically coupled to the drilling machine (during taphole opening) or a mud gun (during taphole closing) to capture electrical signals corresponding to drilling distance and pressure variations. These signals are processed through a dedicated control and computing unit to extract characteristic signatures, enabling precise estimation of key parameters such as cast start time, cast end time, and taphole length. The computer-implemented signal analysis and process control significantly enhance measurement accuracy, operational efficiency, and consistency by eliminating human dependency. The industrial implementation of the system has demonstrated substantial performance gains, including a 60% reduction in clay leakages, a 70% improvement in hammering time, and up to an 80% reduction in taphole downtime, thereby contributing to improved blast furnace productivity.</p>

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Revolutionizing Blast Furnace Operations with Advanced Signal Processing Techniques

  • 期刊论文

  • 发表日期：

    2025年12月29日

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  • Ashish Agrawal,
  • Durgesh Shukla,
  • Sagnik Chowdhury,
  • Jose Martin Korath

摘要

The present work reports the development of an intelligent, automated system for accurate determination of critical cast house parameters in blast furnace operations, addressing the inherent limitations of manual and imprecise practices. The system integrates a sensing device mechanically coupled to the drilling machine (during taphole opening) or a mud gun (during taphole closing) to capture electrical signals corresponding to drilling distance and pressure variations. These signals are processed through a dedicated control and computing unit to extract characteristic signatures, enabling precise estimation of key parameters such as cast start time, cast end time, and taphole length. The computer-implemented signal analysis and process control significantly enhance measurement accuracy, operational efficiency, and consistency by eliminating human dependency. The industrial implementation of the system has demonstrated substantial performance gains, including a 60% reduction in clay leakages, a 70% improvement in hammering time, and up to an 80% reduction in taphole downtime, thereby contributing to improved blast furnace productivity.