Abstract

All of a cast-iron or cast-copper stave cooler's weight is supported inside a furnace containment shell by single gas-tight steel collar on the backside. All the coolant piping in each cooler has every external connection collected and routed together through the one steel collar. A wear protection barrier is disposed on the hot face. Such is limited to include at least one of horizontal rows of ribs and channels that retain metal inserts or refractory bricks, or pockets that assist in the retention of castable cement and/or accretions frozen in place from a melt, or an application of an area of hardfacing that is welded on in bead, crosshatch, or weave pattern.

IPC Classes  ?

• F27D 1/12 - CasingsLiningsWallsRoofs incorporating cooling arrangements
• F27D 9/00 - Cooling of furnaces or of charges therein

Abstract

A stave cooler with a body of cast copper in which are fully disposed a number of independent loops of cooling pipes of CuNi/NiCu only, and each loop having an inlet end and an outlet end fitted with a stainless steel (SS) coupler, and all of which inlet and outlet ends and SS couplers are turned up together for external access in a single grouping. A single steel ribbon band or steel collar opened at two opposite ends, is attached, filled in by, or captured to the body panel of cast copper such that the single grouping of inlet and outlet ends and SS couplers are partially or fully filled inside and made accessible for external coolant hose connections. The steel ribbon band, if filled inside, or the steel collar if not filled inside supports the entire weight of the stave cooler inside a furnace shell through a one-per-stave penetration of the furnace shell. The inlet and outlet ends are externally accessible for coolant connections.

IPC Classes  ?

• F27D 1/12 - CasingsLiningsWallsRoofs incorporating cooling arrangements
• C21B 7/10 - CoolingDevices therefor
• F27D 9/00 - Cooling of furnaces or of charges therein

Abstract

Computer modelling methods and foundry methods for copper- nickel coolant pipes cast-in-copper coolers are combined. First, Computational Fluid Dynamics and/or Finite Element Analysis steps verify geometric computer aided design models and materials choices, point-by-point heat distribution, and heat flows. And second, casting steps to commit an acceptable last thickness iteration of a thermal buffer part in simulation to casting it in a foundry. In the foundry, casting conditions are empirically developed to yield all but slight, unclustered bonding imperfections at a concentric diffusion interface of the pipes and surrounding solidified casting that improve the thermal conductivity of furnace-block coolers that incorporate coolant pipes. The combined methods verify in simulation that operational thermal stresses at the pipe-casting interface stay in-bounds of material stress limits, and that the peak temperatures on the hot face will not rise above 450°C.

IPC Classes  ?

• C21B 7/10 - CoolingDevices therefor
• C21B 7/16 - Tuyères
• F27D 1/12 - CasingsLiningsWallsRoofs incorporating cooling arrangements
• F27B 1/24 - Cooling arrangements

Abstract

A stave cooler for a furnace that always includes a liquid coolant piping cast inside. A stave cooler body includes a hot face and a backside and a liquid coolant piping cast inside between the hot face and the backside. A single steel collar on the backside of each stave is engineered to support the entire weight of the stave cooler. Any and every external connection of the liquid coolant piping are collected and routed together through the single steel collar. These stave coolers are limited to those mountable only from the inside of steel containment shells provided with a matching penetration. The single steel collar and a cover plate accommodate and provide a gas-tight seal by a continuous welding of the single steel collar to each steel containment shell.

IPC Classes  ?

• F27D 1/12 - CasingsLiningsWallsRoofs incorporating cooling arrangements
• C21B 7/10 - CoolingDevices therefor
• F27D 9/00 - Cooling of furnaces or of charges therein

Abstract

Computer modelling methods and foundry methods for copper-nickel coolant pipes cast-in-copper coolers are combined. First, Computational Fluid Dynamics and/or Finite Element Analysis steps verify geometric computer aided design models and materials choices, point-by-point heat distribution, and heat flows. And second, casting steps to commit an acceptable last thickness iteration of a thermal buffer part in simulation to casting it in a foundry. In the foundry, casting conditions are empirically developed to yield all but slight, unclustered bonding imperfections at a concentric diffusion interface of the pipes and surrounding solidified casting that improve the thermal conductivity of furnace-block coolers that incorporate coolant pipes. The combined methods verify in simulation that operational thermal stresses at the pipe-casting interface stay in-bounds of material stress limits, and that the peak temperatures on the hot face do not rise above 450° C.

IPC Classes  ?

• C22C 33/00 - Making ferrous alloys
• F28D 15/02 - Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls in which the medium condenses and evaporates, e.g. heat-pipes
• C22C 33/02 - Making ferrous alloys by powder metallurgy
• G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
• G06F 30/28 - Design optimisation, verification or simulation using fluid dynamics, e.g. using Navier-Stokes equations or computational fluid dynamics [CFD]

Abstract

High heat flux furnace cooler comprise CuNi pipe coils cast inside pours of high purity (99%-Wt) copper. The depth of front copper cover over the pipe coils in the hot face to manufacture into the casting is derived from a projection of thermal and stress conditions existing at the cooler's end-of-campaign-life. CFD and/or FEA analyses and modeling is used for a trial-and-error zeroing in of the optimum geometries to employ in the original casting of CuNi pipe coils in high purity copper casting. Individual pipe coil positions to cast inside a copper casting mold are secured with devices that will not melt, cause thermal shear stresses, or be the source of contaminations or copper defects. Pipe bonding to the casting results because the differential coefficient of expansions of the pipes' and the casting's copper alloys involved do not exceed the yield strength of the casting copper during operational thermal cycling.

IPC Classes  ?

• C21B 7/10 - CoolingDevices therefor
• F27B 1/24 - Cooling arrangements
• F27D 1/12 - CasingsLiningsWallsRoofs incorporating cooling arrangements

Abstract

Many substantially identical refractory bricks are assembled into completed horizontal ring rows neatly nested into laterally curved copper stave coolers surrounding the ring. Each brick “locks” into horizontal channels between pairs of parallel horizontal protruding ribs on the hot faces of the stave coolers. Every stave cooler is provisioned with a full covering of the refractory bricks after the stave cooler is mounted inside a corresponding steel containment shell. None of the refractory bricks are permitted to be finished bridging between adjacent stave coolers in the same horizontal row. Each brick is installed in their respective stave coolers with crushable or deformable mortar filling the channels. Each brick hooks a “toe” just under and into an upper of the pair of horizontal ribs, and then rotates in down with favorably oriented and directed earth's gravity to stay in place at least until a next upper row of bricks in a superior horizontal ring “lock” them in a second way.

IPC Classes  ?

• F27D 1/04 - CasingsLiningsWallsRoofs characterised by the form of the bricks or blocks used
• C21B 7/06 - Linings for furnaces
• F27D 1/14 - Supports for linings
• F27D 1/00 - CasingsLiningsWallsRoofs

Abstract

A water pipe collection box and stave support for a cast copper stave cooler body panel that has disposed within it a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends clustered together in a single group that exits a backside of the copper stave cooler body panel. A cast copper stave cooler body panel that has disposed within a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends clustered together in a single group that exits a backside of the copper stave cooler body panel. A blast furnace having stave cooler body panels variously profiled to fit inside, and where each has disposed within it a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends are clustered together in a single group that exits a backside of each copper stave cooler body panel.

IPC Classes  ?

• F27D 1/00 - CasingsLiningsWallsRoofs
• F27B 1/14 - Arrangements of linings
• C21B 7/10 - CoolingDevices therefor
• F27D 1/12 - CasingsLiningsWallsRoofs incorporating cooling arrangements
• F27D 9/00 - Cooling of furnaces or of charges therein

Abstract

All of a cast-iron or cast-copper stave cooler's weight is supported inside a furnace containment shell by a single gas-tight steel collar on its backside face. All the coolant piping in each cooler has every external fluid connection collected and routed together through the one steel collar. A wear protection barrier is disposed on the hot face. At least one of horizontal rows of ribs and channels retain metal inserts or refractory bricks, or pockets that assist in the retention of castable cement and/or accretions frozen in place from a melt, or an application of an area of hardfacing that is welded on in bead, crosshatch, or weave pattern.

IPC Classes  ?

• C21B 7/10 - CoolingDevices therefor
• F27B 1/24 - Cooling arrangements
• F27D 1/12 - CasingsLiningsWallsRoofs incorporating cooling arrangements
• F27B 3/24 - Cooling arrangements
• C21C 5/46 - Details or accessories
• F28D 1/06 - Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with the heat-exchange conduits forming part of, or being attached to, the tank containing the body of fluid
• F27D 9/00 - Cooling of furnaces or of charges therein

Abstract

At least one row of fixed copper coolers are arranged in a furnace in a cantilevered horizontal shelf inside and fastened to an external steel ring support and the steel containment shell. These shelves redirect and take all the weight of refractory brick and floating cooling blocks that are stacked on above. Each fixed copper cooler in the shelves cantilever shoulder-to-shoulder over any refractory brick and floating cooling blocks that may be stacked beneath to relieve that lower portion of the wall from the weight of the upper wall. When relieved of such weight, the risks of sudden catastrophic failure of the lower walls is reduced. These bricks in the lower walls can also be allowed to wear and thin beyond what would be reasonable in a conventional design without any cantilevered shelving.

IPC Classes  ?

• F27D 1/12 - CasingsLiningsWallsRoofs incorporating cooling arrangements
• F27D 9/00 - Cooling of furnaces or of charges therein

Abstract

All of a cast-iron or cast-copper stave cooler's weight is supported inside a furnace containment shell by single gas-tight steel collar on the backside. All the coolant piping in each cooler has every external connection collected and routed together through the one steel collar. A wear protection barrier is disposed on the hot face. Such is limited to include at least one of horizontal rows of ribs and channels that retain metal inserts or refractory bricks, or pockets that assist in the retention of castable cement and/or accretions frozen in place from a melt, or an application of an area of hardfacing that is welded on in bead, crosshatch, or weave pattern.

IPC Classes  ?

• C21B 7/10 - CoolingDevices therefor
• F27B 1/14 - Arrangements of linings
• F27D 1/00 - CasingsLiningsWallsRoofs
• F27D 1/12 - CasingsLiningsWallsRoofs incorporating cooling arrangements
• F27D 1/14 - Supports for linings
• F27D 1/04 - CasingsLiningsWallsRoofs characterised by the form of the bricks or blocks used
• F27D 9/00 - Cooling of furnaces or of charges therein

Abstract

The campaign lives are extended and the risks of process gas leaks past seals are reduced by improved stave coolers that each hang together inside steel shelled furnaces by a single neck extended out through a steel jacketed collar. All the coolant circuits inside the stave cooler are collected and grouped together to pass inside through the one collar. The steel in the collar is matched to the steel used in the containment shell, and a matching steel weld seals them together. Thermal stresses are thereby prevented from accumulating over separation distances as a consequent of the steel's coefficient of expansion. A single point of penetration has no separation distance to another.

IPC Classes  ?

• C21B 7/10 - CoolingDevices therefor
• F27D 1/00 - CasingsLiningsWallsRoofs
• F27B 1/14 - Arrangements of linings
• F28D 21/00 - Heat-exchange apparatus not covered by any of the groups
• F27D 9/00 - Cooling of furnaces or of charges therein

Abstract

A supporting frame and thin stave cooler for a metallurgical furnace comprises a metal structure fastened to the cold face of the thin stave cooler that adds strength and rigidity. The thin stave cooler itself is lightened, thinned, and simplified to take optimal advantage of the supporting frame and its provisions for mounting and attaching the thin stave cooler assembly to the inside walls of a furnace containment shell. Water is circulated in the thin stave cooler through feed and discharge piping connections that pass through the supporting frame and are sleeved by protection sleeves. The protection sleeves can serve as a primary or secondary support system when they are welded between the furnace containment shell and the supporting frame when first installed.

IPC Classes  ?

• C21B 7/10 - CoolingDevices therefor