This paper gives a systemic study and review of blast furnace cooling stave with refractory lining materials used in the metallurgical industries based on heat transfer analysis. The three dimensional model of heat transfer of cooling stave with refractory lining in a blast furnace are modelled and analyzed with the help of ANSYS software. The model further utilized for the heat transfer analysis of different thickness of lining materials. The Refractory lining material which is used in this experiment are mullite bricks (65%Al2O3&35%SiO2) with different stave materials (copper, aluminium and cast iron). We have identified a stave cooler in RSP(Rourkela steel plant) blast furnace -4 in Bosh zone where heat load is maximum for our experiment purpose. The data collected from RSP is used for developing a 3 D model of heat transfer analysis of refractory lining with stave cooling. We collected the heat flux data of subjected stave cooler and tabulated for our experimental study. The experiment result collaborates with the actual result developed in the 3D model. Further, In this study refractory lining thickness of the blast furnace is taken as 650mm from the inner side of the furnace to the stave body by gradually decreasing the refractory lining thickness up to 550mm. Copper and aluminum is used in place of cast iron as stave material, the factor of safety of the stave material is greatly enhanced due to higher thermal conductivity.
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