Smart Staves

The wear monitoring solution

Blast Furnace Plants

Smart Staves – The Wear Monitoring Solution

Introduction
In terms of blast furnace shell protection, copper staves are considered proven cooling technology to
protect high heat load areas, thereby ensuring a high productivity and a long campaign life of the fur-
nace. To maintain these benefits of the cooling elements, it is essential that blast furnace operators
are able to detect possible premature wear of copper staves at a very early stage so as to prevent
complex replacements or relines.

Taking up this issue, Paul Wurth has developed a new sensor to measure and monitor the stave wear
in a precise and continuous way, whereby all data are transmitted via wireless network to a cloud. The
individual sensors are powered by batteries. The operator then visualises the wear measurements on a
dashboard designed by Paul Wurth. The sensors can be installed on new staves or as a retrofit during
blast furnace stoppage.

Technical features
Sensor
yy Sensor made of copper (same physical properties as staves)
yy Embedded in existing or new cooper staves
yy Sensor wears together with stave
yy Absolute measurement of the stave thickness

Electronic unit
yy Located outside the BF shell
yy Microcontroller with signals processing
yy Battery-powered, no cabling, reduced installation costs
yy Measurement frequency defined by operator

Data processing
yy All data related to wear condition and battery status are encrypted during transmission.
yy Wireless data transmission to secured cloud (Paul Wurth Xpert Cloud)
yy Web-based dashboards adapted to customer’s needs
™
CLOUD

Customers

Process Mobile
Recommendations Dashboards Reports

Data transmisson

0928 19062019 (Brochure) Smart Staves

 Blast Furnace Plants

A smart solution
As the measurement is continuous in time, it becomes possible to make a correlation between the stave
wear and the furnace operation. By using statistical analysis, process models and AI for root cause
analysis, the wear of the cooling elements can be related to the BF process parameters and counter-
measures can be taken to improve the wear situation. Additional process support and process recom-
mendations can be obtained from Paul Wurth in case wear is detected.

“ Being subject to stave wear is not pleasant,

”
but not knowing it is even worse.

Benefits
yy Easy installation during normal shutdown
yy Regular monitoring during operation
yy Full historical data of staves wear
yy Digital feature for lifetime extension of staves
yy Low invest as system is provided as a service
yy Process support by Paul Wurth is available when wear appears
Engineering & Technology worldwide
The Paul Wurth Group is today one of the world leaders in the design and supply of complete
plants, systems and processes as well as specialised mechanical equipment for
 the iron & steel industry:
Blast Furnaces & Auxiliary Plants
Coke Making Plants
Direct Reduction Plants
Environmental Protection, Recycling & Energy-Saving Technologies
 other industries:
Valve Solutions for Oil & Gas Downstream Processes
Solutions for Decentralised Energy Production
Intralogistics Solutions for Heavy Loads
Engineering & Project Management for Civil Construction and Infrastructure Projects

Feasibility Studies – Conceptual, Basic and Detail Engineering – Project Management – Plant and Components Supply –
Turnkey Projects – Digital Solutions – Assistance in Plant Assembly and Commissioning – Technology and Operations
Consultancy – On-site and Remote Operational Assistance – After-sales Services

© Copyright 2019 Paul Wurth S.A. – all rights reserved

Non Contractual Data: Paul Wurth believes that the data contained in this folder are correct and accurate, but cannot guarantee same or better performances for any
specific site without a detailed quote. Patents and Patents pending. — Paul Wurth equipment and processes are protected in many countries by patents.
Paul Wurth and the Paul Wurth Logo are trademarks of Paul Wurth S.A. and may be registered in your jurisdiction.

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Paul Wurth S.A.
Phone: (+7) 49232 97099 Paul Wurth: Belo Horizonte, BRAZIL Phone: (+91) 124 4523200
Luxembourg, LUXEMBOURG
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Phone: (+352) 4970-1
Tapping Measuring Technology pwbm@paulwurth.com
paulwurth@paulwurth.com
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Phone: (+420) 595 155 100 Phone: (+81) 3 6630 4786
Manufacture Co., Ltd
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CTI Systems S.à r.l. Paul Wurth do Brasil Shanghai, CHINA
Paul Wurth Moscow Lentzweiler, LUXEMBOURG Belo Horizonte, BRAZIL Phone: (+86) 21 61186300
Representation Office Phone: (+352) 2685 2000 Phone: (+55) 31 3228 2800 pwshanghai@paulwurth.com
Moscow, RUSSIA cti@ctisystems.com pwbr@paulwurth.com
Phone: (+7) 495 721 1553 www.ctisystems.com
pwmoscow@paulwurth.com

Publisher: Paul Wurth S.A. – Communications & Marketing • 32, rue d’Alsace • L-1122 Luxembourg