Inverse heat transfer prediction of the state of the brick wall of a melting furnace

An inverse heat transfer method for predicting the state of the lateral refractory brick wall of a melting furnace is presented. By collecting temperature data with a thermocouple embedded into the brick wall, the inverse method is able to predict (1) the time-varying thickness of the protective bank that covers the inner lining of the furnace wall; (2) the thermal contact resistance between the inner lining and the protective bank; and (3) the possible erosion of the refractory brick wall. The inverse procedure rests on the Levenberg Marquardt algorithm combined with the Broyden method. The effect (1) of the noise on the collected temperature data; (2) of the thermal diffusivity of the brick wall; (3) of the location of the embedded temperature sensor; and (4) of the Biot number on the inverse predictions is investigated. Recommendations are made for the optimum position of the embedded sensor and its operation.