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Non Ferrous Articles

New and Innovative Non-Destructive Testing (NDT) Techniques for Inspection and Monitoring of Metal Smelting Furnaces
Authors: A. Sadri, P. Gebski, K. Mirkhani and G. McGarrie
NDT in Canada 2009, Conference and the 6th International Workshop: Advances in Signal Processing for Non Destructive Evaluation of the Materials, August 25 - 27, 2009


In this paper, three (3) different NDT techniques are introduced: Acousto Ultrasonic-Echo (AU-E), Taphole Acoustic Monitoring (TAM) and Ultrasonic pulse-echo (UT) for copper cooling element inspection. All three (3) techniques have been developed and implemented for applications in metal smelting furnaces.

The AU-E technique was developed to determine refractory thickness in operating furnaces. In addition, AU-E is capable of determining metal penetration within furnace lining, determining position of cracks in the bricks and delaminations within the sidewall and hearth lining.

TAM is a monitoring system based on the acoustic emission (AE) principals that is utilized to determine the remaining refractory thickness in tapholes, as the furnace is in operation.

UT has been used to determine the remaining copper thickness in cooling elements in finger coolers, staves, plate coolers, breast coolers, and waffle coolers. To achieve accurate measurements, a temperature correction factor for longitudinal wave was used.

Following a brief introduction to the above techniques, various applications and case studies will be discussed.


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