Keeping process disturbances to a minimum helps in prolonging blast furnace campaign life. These disturbances can be rapidly determined by analysing thermal distribution in the wall and other stability indices using statistical techniques and neural networks. This research project will employ wall thermal data and existing mathematical models to recognise disturbances in burden permeability and asymmetric three-phase furnace behaviour. New measurement and monitoring techniques for water leakage, tuyere leakage, iron temperature and hearth thermocouples will be developed to provide rapid warning of poor operation. The monitoring of wall temperatures and internal water leaks (tuyeres, cooling plates) can greatly contribute to avoiding breakouts and other critical situations.