US Steel installs digital tuyere monitoring system at Gary Works

US Steel has commissioned a digital Tuyere Phenomena Detection System (TPDS) supplied by SMS Group on blast furnace No. 14 at its Gary Works in Indiana, marking the first installation of its kind in the United States.

The system monitors operating conditions across all 34 tuyeres, which inject hot blast and, where applicable, supplementary fuels into the blast furnace. It provides operators with a digital view of tuyere conditions from the control room, reducing the need for manual inspections in the tuyere area and improving operational safety.

The TPDS combines tuyere blockage detection with a raceway model and anomaly detection software, helping operators identify abnormal tuyere and raceway behaviour more quickly and improve furnace control.

US Steel project manager Brian Hynes said the system provides remote visibility of tuyere conditions and helps predict certain operating phenomena, supporting safer and more efficient furnace operation.

Founded in 1901, U.S. Steel operates across the U.S. and Central Europe. Nippon Steel, Japan's largest steelmaker, completed its USD 14.9 bln acquisition of the company in June 2025.