Analysis of the Erosion Boundary of a Blast Furnace Hearth Driven by Thermal Stress Based on the Thermal–Fluid–Structural Model

Irreversible erosion damage of the hearth lining determines the campaign life of a blast furnace (BF). Among the factors involved, structural thermal stress resulting from both internal and external temperature differences and external constraints is a key mechanism in the damage to the hearth lining. Based on a thermal–fluid–structural coupling model that accounts for molten iron flow and solidification, this study, building on thermal stress analysis of the hearth lining, proposes a method to determine the critical strength-based erosion boundary of the lining, using the compressive strength of carbon bricks as the criterion. It also investigates the influence of factors such as dead iron layer depth, tapping productivity, and molten iron temperature on the thermal stress-driven erosion boundary. The findings reveal that the depth of the dead iron layer determines the morphology of the hearth lining’s erosion. With increasing depth, the erosion pattern transitions from an elephant foot profile to a wide-face profile, while the radial erosion depth first increases and then decreases. Both increased tapping productivity and elevated molten iron temperature do not change the erosion shape but aggravate the erosion degree and induce axial displacement of the erosion zone. The research findings are of great significance for deepening the understanding of thermal stress damage in the hearth lining and provide an effective reference for long-term hearth design. Subsequent validation with a large amount of industrial data will further enhance the practical applicability of the proposed method.