The blast furnace represents the heart of steel production, and AI is revolutionizing this critical process. Modern blast furnaces equipped with AI systems can optimize burden distribution in real-time, ensuring optimal coke and ore ratios for maximum efficiency.

Real-Time Burden Optimization

AI algorithms analyze sensor data from hundreds of thermocouples and gas analyzers to predict and prevent issues before they occur. Machine learning models learn from historical data to optimize:

• Coke rate reduction by up to 15%
• Hot metal production increase by 5-8%
• Energy consumption optimization
• Predictive maintenance scheduling

Thermal Profiling Intelligence

Advanced AI systems create detailed thermal profiles of the furnace stack, identifying hotspots and cold zones that could indicate operational issues. This allows operators to make precise adjustments to fuel injection and burden distribution.

Campaign Life Extension

By maintaining optimal operating conditions, AI helps extend blast furnace campaign life from 10-15 years to 20+ years, significantly reducing capital investment requirements.

The future of blast furnace operations lies in fully autonomous AI-driven control systems that can adapt to changing raw material quality and market demands in real-time.