Tap-hole monitoring technologies

Abstract

This paper provides a progress update on three tap-block monitoring technologies that Hatch has been developing with our clients for nonferrous smelting furnaces. The Tapblock Diagnostic System (TDS) is an advanced on-line monitoring system that uses temperature data along with embedded thermal model results to evaluate the condition of a tap-block over its campaign life. Hatch recently installed a second TDS and this paper provides some details on this second installation. The Taphole Acoustic Monitoring (TAM) system is installed on watercooled copper tap-blocks and uses the noise from the tapping channel to provide a qualitative indication of wear and deterioration of the tapping channel refractory. In addition, TAM can be used to monitor drilling and lancing performance and potentially could also be used in the future as a guide for automatic drilling and lancing systems. The third technology is the use of fibre optic sensors to measure temperature on the hot face and in the tapping channel of a tap-block. Fibre optic technology allows installation of numerous sensors in key locations where they are very sensitive to tap-block condition, and also provide more extensive spatial coverage than is possible with traditional instruments. This paper provides an update on our efforts to address issues with premature failure of the sensor cables due to corrosion, and also to turn the vast amount of data from the sensor cable into information that can be used by furnace operators.