A stave cooling system is a key element in the blast furnace which protects the outer shell from heat by providing uniform cooling. Real-time condition assessment of staves is essential to understand the wear mechanism of staves. Inspection rod/waveguide of known length which is made of copper was inserted through the steel shell till the inner end of the stave where the waveguide is susceptible to reduce in length as stave erodes with time. FEM analysis was done to find the ultrasonic parameters and lab-scale trials were taken on artificial waveguides with different end conditions. Based on the results, an ultrasonic-based real-time thickness measurement system was developed to continuously measure the length of the inspection rod/waveguide which eventually represents the stave thickness. System was installed in the plant, the data was captured and shown for 60 days from the date of the installation with an accuracy of more than 98%.
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