Grant: Collaborative Research and Development Grants

Accurate knowledge of molten metal levels in pyrometallurgical furnaces is desired in order to optimize when and for how long tapping operations should be performed. In addition, proximity of molten metal, as measured from the furnace side wall, can provide an estimate of remaining refractory wall, an important gauge of the furnace's long term structural integrity. This work will focus on challenges to develop a novel electromagnetic field sensing system that could be used to remotely monitor the level and proximity of molten metal inside a pyrometallurgical furnace. This capability is not presently addressed by existing, commercially available, inspection systems. The technology used for this project will be eddy current based, which has demonstrated its capability to perform inspection at larger distances for various applications, such as metal detection. This proposal is an extension of our previous experimental work using eddy current based technology, which demonstrated the feasibility of detecting molten metal level combined with sensitivity to metal proximity under simulated pyrometallurgical furnace conditions. The main focus of this phase of work is to address the signal processing required to separate and report the two key desired process parameters, metal level and metal distance, from the measured eddy current signals. Following the approach used in the first phase, the work will involve computer modelling and tests using actual coils in a laboratory setting. The eventual target is to build a prototype for testing in an actual furnace. This will require optimization of parameters, such as coil geometry, coil spacing and initial distance to molten metal bath. In addition, there are other parameters, which can affect the measurements, such as high temperature, proximity of other metal conductors and background noise in an actual furnace, which need to be explored.