CONJUNTO DE RESFRIAMENTO PARA RESFRIAR GASES DE EXAUSTÃO EMITIDOS A PARTIR DE UM FORNO DE FABRICAÇÃO DE AÇO, E, SISTEMA DE TROCA DE CALOR

Description

25 Cooling unit for cooling exhaust gases emitted from a steelmaking furnace, and heat exchange system. DIVIDED FROM BR112023008172-6, DEPOSITED ON 01 / 11 / 2021 RELATED ORDERS

[001] This application claims the benefit of the Patent Application. United States Provisional Trademark Serial No. 63 / 108474, filed November 2, 2020, the description of which is incorporated herein by reference in its entirety. DESCRIPTION FIELD

[002] The present invention generally relates to a method and apparatus for extending the operational life of electric arc furnaces, metallurgical furnaces, including metal smelting and refining furnaces. In particular, the description refers to heat exchange systems used to protect such equipment. FUNDAMENTALS

[003] The use of cooling elements to protect equipment used in various processes in the steel industry is well known. This equipment may need to operate under extreme heat flow conditions. Conventional cooling elements typically comprise a plurality of tubes or pipes with water flowing through them, coupled together to form the cooling elements. Such conventional tubes may, for example, be cylindrical tubes with an internal diameter (“ID”) of 6.35 centimeters (2.5 inches) having maximum water velocities through the tubes of about 1.82 to 2.13 meters (six (6) to seven (7) feet) per second. The high heat flow conditions under which these tubes may operate make it desirable to have higher heat transfer rates and higher water velocities than conventional 6.35 centimeter (2.5 inch) internal diameter tubes can offer. It is also Petition 870260048552, dated 05 / 21 / 2026, page 11 / 52 / 25 desirable to be able to choose to manufacture the tubes and resulting elements from any suitable material and using any manufacturing method suitable for the material to be used. SUMMARY

[004] In one embodiment of the present description, a cooling assembly for cooling exhaust gases emitted from a steelmaking furnace includes a plate configured to be coupled to the furnace, the plate having a first surface and a second surface, the first surface being opposite the second surface; a body comprising a defined length and a cross-sectional shape having a defined thickness between an outer surface and an inner surface thereof, the body including a first mounting end and a second mounting end; wherein the first mounting end is mounted on the first surface at a first angle greater than 0°; wherein the second mounting end is mounted on the first surface at a second angle greater than 0°, the second mounting end spaced from the first mounting end;where a conduit is defined between the inner surface and the first surface for a cooling fluid to flow through it.

[005] In this embodiment, the first angle may be approximately equal to the second angle. Alternatively, the first angle may be different from the second angle. Furthermore, the first angle and the second angle may each be between 15° and 45°. In addition, the assembly may include a second body comprising a defined length and a cross-sectional shape having a defined thickness between an outer surface and an inner surface thereof, the second body including a first mounting end and a second mounting end; wherein the first mounting end of the second body is mounted at an angle to the first surface at a location Petition 870260048552, dated 05 / 21 / 2026, page 12 / 52 / 25 adjacent to the second mounting end of the body; wherein the body and the second body are mounted on the first surface so that their respective lengths are parallel to each other.

[006] In this embodiment, the body and the second body can be welded to the first surface so that a single weld is arranged between the angled ends of the first mounting end of the second body, the second mounting end of the body, and the first surface. Furthermore, the body can be made of steel, iron, nickel, or an aluminum bronze alloy.

[007] In another embodiment of the present description, a cooling assembly for cooling the exhaust gases emitted from a steelmaking furnace includes a body configured to be coupled to a furnace mounting surface, the body comprising a defined length and a cross-sectional shape having a defined thickness between an outer surface and an inner surface thereof, the body including a first mounting end and a second mounting end; wherein the body comprises a first portion, a second portion and an intermediate portion formed integrally between the first and second portions; wherein the first mounting end is formed integrally into the first portion, the first mounting end comprising a first end surface that is angularly coupled to the mounting surface;wherein the second mounting end is integrally formed in the second portion, the second mounting end comprising a second end surface that is angularly coupled to the mounting surface at a spaced location from the first mounting end; wherein a first fluid conduit is defined between the inner surface of the first portion and the mounting surface; wherein a second fluid conduit is defined between the inner surface of the second portion and the surface of; Petition 870260048552, dated 05 / 21 / 2026, page 13 / 52 / 25 assembly.

[008] In this embodiment, the intermediate portion may include a defined width between the first portion and the second portion, wherein the intermediate portion comprises a substantially flat surface disposed in contact with the mounting surface along the defined width. Furthermore, the first portion may be in contact with the mounting surface at a first point of contact; the second portion may be in contact with the mounting surface at a second point of contact; the first point of contact and the second point of contact each being a single point of contact at any location along the length of the body.Furthermore, the first portion may be in contact with the mounting surface at a first point of contact; the second portion may be in contact with the mounting surface at a second point of contact; the intermediate portion may be in contact with the mounting surface along its width, where the contact between the intermediate portion and the mounting surface is greater than a combined contact of the first and second portions with the mounting surface.

[009] In this form, the body can be made of steel, iron, nickel, or an aluminum bronze alloy.

[0010] Also in this embodiment, the mounting surface may be formed from a plate having defined length, width and thickness, the plate comprising an opening formed in it; the body being coupled to the mounting surface so that the intermediate portion is aligned with the opening in the plate.

[0011] In addition, a coupling mechanism may be provided to couple the intermediate portion to the plate at the location of the opening. In one aspect, the coupling mechanism comprises a weld.

[0012] In this embodiment, a first weld may be arranged between the first mounting end and the mounting surface; and a Petition 870260048552, dated 05 / 21 / 2026, page 14 / 52 / 25 The second weld may be placed between the second mounting end and the mounting surface.

[0013] Furthermore, in this embodiment, the cooling assembly may include a second body comprising a defined length and a cross-sectional shape having a defined thickness between an outer surface and an inner surface thereof, the second body including a first mounting end and a second mounting end; wherein a third conduit is defined between the inner surface of the second body and the mounting surface, wherein the third conduit is aligned substantially parallel to the first and second conduits.

[0014] Furthermore, in this embodiment, the second mounting end of the body can be coupled to the mounting surface adjacent to the first mounting end of the second body. Additionally, a single weld can couple the second mounting end of the body and the first mounting end of the second body to the mounting surface.

[0015] In a further embodiment of the present description, a heat exchange system includes a furnace having means for heating a furnace interior and generating hot exhaust gases; a winding pipe panel having an inlet and an outlet, the pipe forming a fluid passage through which a cooling fluid flows between the inlet and the outlet; an inlet manifold in fluid communication with the panel inlet; an outlet manifold in fluid communication with the panel outlet; the pipe comprising a body configured to be coupled to a furnace mounting surface, the body comprising a defined length and a cross-sectional shape having a defined thickness between an outer surface and an inner surface thereof, the body including a first mounting end and a second mounting end; wherein the body comprises a first portion, a second Petition 870260048552, dated 05 / 21 / 2026, p.15 / 52 / 25 portion and an intermediate portion formed integrally between the first and second portions; wherein the first mounting end is formed integrally in the first portion, the first mounting end comprising a first end surface that is angularly coupled to the mounting surface; wherein the second mounting end is formed integrally in the second portion, the second mounting end comprising a second end surface that is angularly coupled to the mounting surface at a spaced location from the first mounting end; wherein a first fluid conduit is defined between the inner surface of the first portion and the mounting surface, the first fluid conduit forming a portion of the fluid passage; wherein a second fluid conduit is defined between the inner surface of the second portion and the mounting surface, the second fluid conduit forming another portion of the fluid passage. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 illustrates a flowchart of a melting process in a metallurgical furnace; Figure 2 illustrates a single half-pipe cooling element; Figure 3 illustrates a double half-pipe cooling element; Figure 4 illustrates a perspective view of a combined single and double half-pipe cooling assembly; Figure 5 illustrates a front view of the assembly in Figure 4; and Figure 6 illustrates a lower front perspective view of the assembly in Figure 4. DETAILED DESCRIPTION

[0017] In an electric arc furnace (EAF), a portion above a furnace hearth or casting area must be protected against high temperatures. Petition 870260048552, dated 05 / 21 / 2026, page 16 / 52 / 25 internal furnace temperatures. The wall, roof or ceiling, and the work in the furnace vessel duct are particularly at risk of massive thermal, chemical, and mechanical stresses caused by steel loading. Such stresses significantly limit the furnace's operational life. The furnace vessel is generally designed and manufactured as a welded steel structure that is protected against the high temperatures inside the furnace vessel by a refractory lining and water-cooled panels. The water-cooled ceiling panels and the water-cooled wall side panels are located in portions of the furnace vessel above the furnace's melting / casting area.

[0018] In addition, furnace effluent gas ducts are also composed of a plurality of pipes around their circumference that protect the duct network from the high temperatures and caustic gases produced during furnace operation. Existing water-cooled panels and ducts are manufactured with various grades and types of plates and pipes. The use of water-cooled panels reduces refractory costs, allows steelmakers to operate each furnace for a greater number of heatings, and allows furnaces to operate with increased power input and chemical energy levels. These panels are designed to incorporate a plurality of serpentine-shaped pipes and hang from the inner wall of the electric arc furnace above the furnace hearth, thus forming a cooling surface between the interior and the furnace wall.

[0019] It is important to maintain a slag layer on the hot side of water-cooled panels to protect the panels from thermal degradation and arcing during normal furnace operation. Specially designed extruded slag cups, slag rods, slag pins, and tubing with grooves on the hot side surface of the tubing can be used to retain slag splashed onto the hot side surface of the panels. Petition 870260048552, dated 05 / 21 / 2026, page 17 / 52 / 25 The slag solidifies in the pipes, forming an insulating barrier between the cast iron material and the cooling pipes, and consequently, the furnace wall.

[0020] With reference to Figure 1, an embodiment of a furnace is illustrated as an EAF 180 type furnace. While the EAF is described as an example, it is understood that the principles and teachings of the present description can be readily applied to a basic oxygen furnace (BOF) and the like. In Figure 1, an EAF 180 may include a furnace shell 112, a plurality of electrodes 114, an exhaust system 116, a work platform 118, an oscillating tilt mechanism 120, a tilt cylinder 122, and a shut-off gas chamber. The furnace shell 112 may be movably arranged on the oscillating tilt 120 or other tilt mechanism. Furthermore, the oscillating tilt 120 may be fed by the tilt cylinder 122. The oscillating tilt 120 may also be further secured on the work platform 118.

[0021] The furnace casing 112 may include a domed furnace hearth 124, a generally cylindrical side wall 126, a nozzle 128, a nozzle gate 130, and a general cylindrical circular roof 132. The nozzle 128 and the nozzle gate 130 are located on one side of the cylindrical side wall 126. In the open position, the nozzle 128 may allow invading air 134 to enter the furnace hearth 124 and partially burn the gases 136 produced from the smelting. The furnace hearth 124 is formed of a suitable refractory material. At one end of the furnace hearth 124 is a pouring box having a tapping means 138 at its lower end. During a melting operation, the tapping means 138 is closed by a refractory plug or a sliding door.After that, the furnace shell 112 is tilted, the tap 138 is disconnected, or the open, molten metal is poured into a pouring pan, intermediate pan, or other device, as desired. Petition 870260048552, dated 05 / 21 / 2026, page 18 / 52 / 25

[0022] The inner wall 126 of the furnace casing 112 may be fitted with water-cooled panels 140 with winding piping 150. The panels, in effect, serve as an inner wall in the furnace 180. The manifolds, which supply cold water and a return, are in fluid communication with the panels 140. Typically, the manifolds are positioned peripherally in a manner similar to the exhaust ducts illustrated 144.

[0023] The heat exchanger system 110 produces more efficient operation and extends the service life of the EAF 110 furnace. In an illustrative embodiment, the panels 140 can be mounted so that the winding pipe has a generally horizontal orientation. The pipe 150 can be connected to a fitting or have a base mounted on the wall. Alternatively, the panels 140 can be mounted so that the winding pipe 150 has a generally vertical orientation. The upper edges of the panels 140 can define a circular rim on the upper edge of the side wall portion 126 of the furnace 180.

[0024] The heat exchanger system 110 can be mounted on the roof 132 of the furnace 180, wherein the water-cooled panels 140 have a curvature that substantially follows the vaulted contour of the roof 132. The heat exchanger system 110 can be deployed inside the side wall 126 of the furnace 180, on the roof 132 and at the exhaust system inlet 116, as well as throughout the exhaust system 116. As such, the heat exchanger system 110 can protect the furnace and cool the hot waste gases 136 as they are conveyed to a filter chamber or other air filtration and treatment facilities, where dust is collected and gases are vented to the atmosphere.

[0025] In operation, hot waste gases 136, dust and vapors are removed from the furnace hearth 124 through a vent 146 in the furnace casing 112. The vent 146 may be in communication with Petition 870260048552, dated 05 / 21 / 2026, p. 19 / 52 / 25 an exhaust system.

[0026] Panel 140 may have a plurality of axially arranged pipes 150. U-shaped elbows may connect adjacent pipe lengths or pipes 150 together to form a continuous piping system. Connections and similar fittings that additionally serve as spacers may be between adjacent pipes 150 and provide structural integrity to panel 140 and are determinants of the curvature for panel 140.

[0027] The heat exchange system or heat exchanger 110 may include at least one panel of winding tubing 150 having an inlet (not shown) and an outlet (not shown), an inlet manifold in fluid communication with the inlet of at least one panel, an outlet manifold in fluid communication with the outlet of at least one panel, and a cooling fluid flowing through the tubing 150. The heat exchanger system 110 cools the hot steam gases 136 and dust being evacuated from the metallurgical furnace 180 and its supporting components. The tubing is an assembly of connected sectional lengths of tubes mounted side by side, wherein the connected tubes are fastened to each other with the connection, forming at least one panel 150.

[0028] It has been determined that an illustrative and desirable composition for the manufacture of 150 tubing is an aluminum bronze alloy. Aluminum bronze alloys have been found to exhibit higher than expected thermal conductivity, resistance to corrosion by hot gas streams (modulus of elasticity), and good oxidation resistance. Thus, the service life of the heat exchanger is extended. Corrosion and erosion of the heat exchanger and related components are reduced when manufactured with aluminum bronze. Aluminum bronze has a thermal conductivity that is 41% higher than P22 (approximately 96% Fe, 0.1% C, 0.45% Mn, 2.65% Cr, 0.93% Mo) and 30.4% higher than carbon steel (A106B). Heat exchangers Petition 870260048552, dated 05 / 21 / 2026, page 20 / 52 / 25 manufactured with aluminum bronze and alloys thereof are more efficient and have a longer operational life than furnaces constructed with refractory materials and / or other metal alloys.

[0029] It was also determined that 150 pipe can be extruded and that extrusion can help the pipe resist corrosion, erosion, pressure, and thermal stress. The pipe can be bent or curved to match the curvature of a wall to which it is being attached, if necessary. More typically, individual sections of the pipe are fastened together with an angle connection, so that the resulting panel has a curvature comparable to the curvature of the wall.

[0030] In the embodiment of Figure 1, the sinuous pipe 150 can be formed by a plurality of longitudinal pipe sections in which two of the pipe sections are connected by an elbow. It is often difficult to assemble these sections into elbows and the present description provides an arrangement to better facilitate and improve the welding process.

[0031] Illustratively, fluid-cooled elements resistant to high heat flow having relatively high heat transfer rates and high water velocities are provided according to the present description. It will be recognized that the elements may have any suitable fluid, such as a liquid including, for example, water flowing through them. The present description provides a means of selecting a wider range of materials for the manufacture of user-selectively molded and designed water-cooled elements for applications in the steel industry. As noted, liquids or coolants other than water also fall within the scope of the present description. The elements will have the ability to better withstand the harsh and constantly changing requirements in furnaces, combustion gas systems, exhaust gas tanks, cylinders, combustion chambers, disposal boxes, etc.due to the inherent and enhanced speed of the refrigerant inside the(s). Petition 870260048552, dated 05 / 21 / 2026, page 21 / 52 / 25 tube(s) / element(s) and the resulting increase in heat transfer capacity. This present description allows the selection of manufacturing material and manufacturing method including, for example, by rolling, forging, casting or extrusion, as desired, for the cross-sectional radius required or desired to optimize heat transfer and elasticity requirements for the specific application and without limitation to current requirements for selecting tube / pipe materials that are commercially available.

[0032] With reference to Figure 2, a cooling element 200 or heat exchange apparatus in the form of a single half-pipe 202 or half-tube 202 is formed into a desired shape, such as, for example, a half-pipe 202 having a cross-section approximating a circle or polygon substantially divided into two parts, including a quadrilateral, a parallelogram, a hexagon or an octagon in cross-section. In other words, the half-pipe 202 may illustratively approximate a polyhedron or cylinder substantially divided in half along a plane of one diameter thereof to form a semipolyhedron or the illustrative semicylindrical body represented 202 as described below.The illustrative bisected or semi-cylindrical body or half-pipe 202 extends from a first mounting end 204 to a second opposite mounting end 206 to define an arched and generally concave inner surface 208 and an arched and generally convex outer surface 210 forming an arc, respectively, between the mounting ends 204, 206. In other words, the single tube or half-pipe 202 represents half of a diametrically divided or substantially bisected cylindrical body.

[0033] The opposite mounting ends 204, 206 are configured illustratively for mounting or coupling the single half pipe 202 to, for example, a mounting plate 400, as shown. Petition 870260048552, dated 05 / 21 / 2026, page 22 / 52 / 25 in Figure 4. It will be recognized that the single half-pipe 202 can be mounted directly onto a piece of equipment, such as, for example, a furnace wall 180. In Figure 4, the single half-pipe 202 is shown mounted or coupled to the pipe mounting face 402 of the mounting plate 400 to form an illustrative cooling element 200. The single half-pipe 202 can include a defined length, L, which can be selected based on the desired heat transfer characteristics and the space available for the pipe. Opposite the pipe mounting face 402 of the mounting plate 400 is an equipment mounting face 404, which is illustratively configured to mount the plate 400 onto a piece of equipment.

[0034] The single half-pipe 202 can be mounted or coupled to the plate 400 in any suitable manner, including, for example, welding along the length of the pipe 202 on each side or mounting end 204, 206 thereof. For example, as shown in Figure 5, the single half-pipe 202 can be mounted by means of a first weld 500 along the first end 204 and a second weld 502 along a second end 206 thereof. Each of the first and second welds can be watertight welds to protect the integrity of the pipe 202 and prevent leakage of fluid that may flow through an internal passage or channel 406 of the single half-pipe 202.

[0035] As shown in Figure 2, each mounting end 204, 206 can be inclined relative to the bisector plane (i.e., the dashed line in Figure 2) or plate 400. In one example, the mounting end 204, 206 may comprise an angle Θ, where Θ is greater than 0°. In a non-limiting example, the angle Θ may be greater than 0° but less than 90°. In a second non-limiting example, the angle Θ may be greater than 0° and less than 75°. In a third non-limiting example, the angle Θ may be greater than 0° and less than 60°. In a fourth non-limiting example Petition 870260048552, dated 05 / 21 / 2026, page 23 / 52 / 25 limiting, the angle Θ can be greater than 0° and less than 45°. In a fifth non-limiting example, the angle Θ can be greater than 15° and less than 45°. In a sixth non-limiting example, the angle Θ can be greater than 30° and less than 45°. In another non-limiting example, the angle Θ can be approximately between 30 and 40°, where approximately is defined as being within 2 to 3°.

[0036] Due to the angled mounting ends, each mounting end can contact the surface 402 of the mounting plate 400 or furnace wall at a single point on its end in the cross-sectional view of Figure 2. With the mounting end having approximately the same length as the entire half-pipe cooling element 200, the mounting end can contact the surface at this point along the entire length of the mounting end.

[0037] With the mounting ends angled, the first weld 500 and the second weld 502 may be disposed between a top surface of the mounting face of the plate 400 or wall and at least a portion of a bottom surface of the respective mounting end 204, 206. This additionally allows a tight seal between them to prevent or inhibit leakage of a cooling fluid flowing through the cooling element or half-pipe. Furthermore, the respective mounting end is more securely held to the mounting surface with the weld being stronger than if the bottom surface of the mounting end were located flush with the mounting surface.

[0038] Any single half-pipe assembly end 204, 206 may, illustratively and optionally, have an extended portion or flange (not shown). For example, when the 204, 206 assembly ends of adjacent pipes have a flange or portion that... Petition 870260048552, dated 05 / 21 / 2026, p. 24 / 52 / 25 extends radially, a weld can be used to fix or attach to plate 400 or piece of equipment these respective ends 204, 206 along their lengths.

[0039] When a single half-pipe 202 and plate 400 are coupled together, channel 406 is formed and configured to contain and permit the passage thereto of a fluid including, without limitation, any suitable refrigerant, such as, for example, a liquid. A non-exclusive example of a suitable liquid is water. Conduit or channel 406 may also be formed by directly assembling together a single half-pipe 202 and a piece of equipment. It will also be recognized that conduit or channel 406 may be formed by forming a closed pipe 202 having a generally flat surface extending between the mounting ends 204, 206 along a diametrical plane. This illustrative surface, which need not be flat or planar, may be assembled together with plate 400 or directly with a piece of equipment.

[0040] The single half-pipe 202 may include several dimensions, including, without limitation, an inner diameter representing the length of the diametral plane extending between the mounting ends 204, 206. As a result, the inner radius 212 and the outer radius 214 represent, respectively, the length of a plane between a midpoint of the diametral plane and any point on the respective inner surface 208 and outer surface 210. These dimensions may be selected as desired.

[0041] With reference now to Figure 3, another embodiment of a cooling element is shown. Here, the cooling element is represented in the form of a double half-pipe 300 or tube. The double half-pipe 300 can be produced as a pair of single half-pipes 202, but as a single unit. The double half-pipe 300 of Figure 3 is shown having a first half-pipe portion 302 and a second half-pipe portion 304. The first and second portions can Petition 870260048552, dated 05 / 21 / 2026, page 25 / 52 / 25 to be formed in a desired shape, such as, for example, having a cross-section that approximates a substantially bisected circle or polygon, including a quadrilateral, a parallelogram, a hexagon or octagon in cross-section. In other words, each portion may approximate a polyhedron or cylinder substantially bisected along a plane of one diameter thereof to form a semipolyhedron or the illustrative semicylindrical body represented 302, 304 as described below.

[0042] The first half-pipe portion 302 and the second half-pipe portion 304 may be integrally formed with a third or intermediate portion 306 defined between them. The intermediate portion 306 may have a substantially flat surface 312 or contact portion where it may be mounted on a plate 400 or other equipment. The intermediate portion 306 may comprise a defined width or distance, d, between the first and second pipe portions, as shown in Figure 3.

[0043] In the embodiments illustrated in the present description, the double half-pipe cooling element 300 is shown with only one pair of half-pipe portions with a single integrally formed intermediate portion between them. However, the present description is not intended to be limited to this configuration. Instead, it may be possible to have two or more half-pipe portions with a respective intermediate portion formed between each pair of half-pipe portions. Thus, in one embodiment, a cooling element may include three half-pipe portions and a pair of integrally formed intermediate portions between each of the two pairs of half-pipe portions. In a further embodiment, a cooling element may include four half-pipe portions and three integrally formed intermediate portions between two of the four half-pipe portions. In yet another embodiment, a cooling element Petition 870260048552, dated 05 / 21 / 2026, page 26 / 52 / 25 may include X number of half-pipe portions and Y intermediate portions, where X is > 2 and Y is equal to X-1.

[0044] The illustrative bisected or semi-cylindrical body or half-pipe portion 302, 304 may extend from a first mounting end 308 to a second opposite mounting end 310 to define an arched and generally concave inner surface 318 and an arched and generally convex outer surface 320 forming an arc respectively between the mounting ends 308, 310. The distance between the mounting ends 308, 310 may be further defined as the sum of an inner diameter of the first half-pipe portion 302, an inner diameter of the second half-pipe portion 302 and the width or distance, d, of the intermediate portion 306.

[0045] Each half-pipe portion of a cooling element may include several dimensions, including an inner radius 314 and an outer radius 316, respectively, representing the length of a plane between a midpoint of the diametral plane and any point on the respective inner surface 318 and outer surface 320. These dimensions may be selected as desired. The thickness of each half-pipe portion may be defined as the difference between the inner and outer radii or surfaces. In one example, the thickness of each portion may be uniform. In another example, the thickness may vary from one end to the opposite end. In a further example, the thickness of the half-pipe portion may be the same as the thickness of the intermediate portion. In other words, the thickness of the intermediate portion may be approximately the same as the difference between the outer radius 316 and the inner radius 318.This difference in radii may be uniform between the first end 308 and the second end 310. In an alternative example, the difference between the outer radius and the inner radius of the first half-pipe portion 302 may differ from the difference between the outer radius and the inner radius of the... Petition 870260048552, dated 05 / 21 / 2026, page 27 / 52 / 25 second portion of half pipe 304.

[0046] As shown in Figure 3, each mounting end 308, 310 can be inclined relative to the bisector plane (i.e., the dashed line in Figure 3) or plate 400. In one example, each mounting end 308, 310 can comprise an angle Θ2, where Θ2 is greater than 0°. In a non-limiting example, the angle Θ2 can be greater than 0° but less than 90°. In a second non-limiting example, the angle Θ2 can be greater than 0° and less than 75°. In a third non-limiting example, the angle Θ2 can be greater than 0° and less than 60°. In a fourth non-limiting example, the angle Θ2 can be greater than 0° and less than 45°. In a fifth non-limiting example, the angle Θ2 can be greater than 15° and less than 45°. In a sixth, non-limiting example, the angle Θ2 can be greater than 30° and less than 45°. In another non-limiting example, the angle Θ2 can be approximately between 30 and 40°, where approximately is defined as being within 2 to 3°.The angle of the first mounting end 308 may be substantially the same as the second mounting end 310 in one embodiment, where substantially it is within 2 to 3 degrees. In another embodiment, the angle of the first mounting end 308 may be substantially different from the second mounting end 310, that is, the difference is greater than 3 degrees.

[0047] Due to the angled mounting ends, each mounting end 308, 310 can contact the surface 402 of the mounting plate 400 or furnace wall at a single point on its end in the cross-sectional view of Figure 3. For example, the first mounting end 308 can contact the surface 402 at a first contact point 324 and the second mounting end 310 can contact the surface 402 at a second contact point 326, where the first and second contact points Petition 870260048552, dated 05 / 21 / 2026, page 28 / 52 / 25 are spaced. The first mounting end 308 may comprise a first end surface 322 that contacts surface 402 at the first contact point 324, but the remainder of the first end surface 322 may not contact surface 402. Similarly, the second mounting end 310 may comprise a second end surface 328 that contacts surface 402 at the second contact point 326, but the remainder of the second end surface 328 may not contact surface 402. With the mounting ends having approximately the same length as the entire half-pipe cooling element 300, the mounting end may contact the surface at this point along the entire length of the mounting end.

[0048] With mounting ends 308, 310 being angled, a first weld 508 and a second weld 510 may be disposed between a top surface 402 of the mounting face of the plate 400 or furnace wall and at least a portion of a bottom surface 322, 328 of the respective mounting ends 308, 310. This further allows for a tight seal between them to prevent or inhibit leakage of a cooling fluid flowing through the cooling element or half-pipe. In addition, the respective mounting end is more securely held to the mounting surface with the weld being stronger than if the bottom surface of the mounting end were located flush with the mounting surface.

[0049] In Figure 3, the 300 double half-pipe can be selectively manufactured from any suitable material, including, for example, steel (e.g., stainless steel, cast steel, extruded steel and drawn steel), iron, including cast iron, nickel, including nickel alloy, as well as any other suitable element, composite or alloy, such as aluminum bronze alloys. Furthermore, material selections for the 300 pipe or tube are available. Petition 870260048552, dated 05 / 21 / 2026, page 29 / 52 / 25 can be selected from a wider range of flat or molded materials, which can be rolled, forged, cast or extruded into the desired semicircular cross-section or semicylindrical shape, which improves the operability of the cooling element compared to the circular tube of the prior art and cooling elements formed therefrom. The greater heat transfer of the present description may have the effect of improving the longevity of the equipment, as well as online reliability and uptime because the equipment will be better suited to withstand the effects of high heat flux, corrosive and abrasive atmosphere in the furnace, combustion gas system or combustion chamber and any other equipment protected by one or more sets of such element(s).

[0050] In one embodiment of the present description, a method is provided for manufacturing a multi-pipe cooling element. Here, a length of bar material (material to be selected based on the application requirement known to those skilled in the art) can be rolled, formed, cast or extruded into one or more desired arcs along its length to meet the cross-sectional area requirement of the cooling element. The material can be selectively manufactured from any suitable material, including, for example, steel (e.g., stainless steel, cast steel, extruded steel and drawn steel), iron (e.g., cast iron), nickel (e.g., nickel alloy), as well as any other suitable element, composite or alloy including, for example, aluminum bronze alloys.

[0051] The material can be selected as being substantially flat for the manufacturing process. The intermediate portion between each arc or half portion can be formed simultaneously during this manufacturing process. The cross-sectional area can be adjusted to meet the desired coolant velocity, pressure drop, and residence time in the cooling element required to optimize life. Petition 870260048552, dated 05 / 21 / 2026, page 30 / 52 / 25 operational of the cooling element.

[0052] In this embodiment, the entire length of the bar may have a generally consistent geometry throughout its length. Each arc or half portion that is rolled, formed, cast, or extruded may generally be an arc of approximately 180 degrees from end to end to simulate a half-pipe / multiple-tube arrangement. The resulting arcs may also be designed to have flanges or tabs at their opposite ends to allow the plurality of tubes to be welded together. The outer surface may generally be smooth or incorporate geometries as required for a specific application, such as, for example, any slag retention devices, including ridges, grooves, heat sinks, or any notches.The double or multiple half-pipe cooling element 300, as shown in Figure 3, may have advantages over the single half-pipe cooling element 200 of Figure 2 due to its ease of manufacture and may provide better performance due to the elimination of almost half the welding. In particular, the cooling element 300 of Figure 3 comprises two or more half-pipes manufactured as a unit, for example, by extrusion or forming. As such, the manufacture of this type of cooling element can eliminate approximately 50% of the welding, which consequently can avoid possible weld defects and failures associated with a single half-pipe cooling element.

[0053] With reference to the embodiment of Figure 4, a double half-pipe cooling element 300 is shown mounted on a plate 400 adjacent to a single half-pipe cooling element 200. This type of arrangement is possible according to the teachings of the present description. When mounted on the plate 400 or equipment, the first half-pipe portion 302 defines a conduit or channel 410 between the inner surface 318 thereof and the mounting surface 402 of the plate 400. As Petition 870260048552, dated 05 / 21 / 2026, page 31 / 52 / 25 result, a refrigerant, such as water, can flow through conduit or channel 410. Similarly, the second half-pipe portion 304 defines a conduit or channel 408 between its inner surface 318 and the mounting surface 402 of plate 400. Furthermore, a refrigerant, such as water, can flow through conduit or channel 408 in a direction that is approximately parallel to that in which a refrigerant flows in the other conduits or channels 406, 410.

[0054] In an alternative embodiment, a system using single and / or double half-pipes may have a first fluid source (e.g., water) and a second fluid source (e.g., air or other refrigerant). The system may be designed so that the first fluid source is fluidly coupled to the first channel 410 and the second fluid source is fluidly coupled to the second channel 408. Alternatively, the first fluid source may be fluidly coupled to each channel 406 of the single half-pipes 200 and the second fluid source may be fluidly coupled to each channel 408, 410 of the double half-pipes 300. Other arrangements are possible, but the use of more than one fluid is possible. For example, in some embodiments, there may be two or more fluid sources so that two or more different fluids may pass through the various channels or conduits to help provide cooling to the furnace.

[0055] Figures 5 and 6 show the combined cooling elements. Specifically, the manner in which the double or multiple half-pipe cooling element 300 is mounted or otherwise coupled to the mounting plate or other surface (e.g., furnace wall or other equipment) is illustrated. Here, for example, the first end 308 can be welded by means of a first weld 508 and the second end 310 can be welded by means of a second weld 504. Each weld is desirably a leak-tight weld to prevent any Petition 870260048552, dated 05 / 21 / 2026, page 32 / 52 / 25 leakage of refrigerant flowing through the half-pipes and to further protect against any moisture or corrosion of the piping. Although it is shown that the half-pipes are coupled or mounted to plate 400 by means of welding, it should be recognized that other forms of coupling or fixing the cooling element 300 to plate 400 can be implemented. Depending on the application and environment, the cooling element 300 can be mechanically coupled by means of a fastener, adhesive or any other means known besides welding. In addition, an adhesive or a mechanical fastener can couple the intermediate portion 306 to plate 400 or wall, while welding, adhesive or other means of coupling can be used to couple the mounting ends to it.

[0056] Although in Figure 5 the single half-pipe cooling element 200 and the double half-pipe cooling element 300 are shown welded to plate 400 with their own welds, it is possible in an alternative embodiment where the second weld 502 and the first 508 are a single weld. Furthermore, in this embodiment illustrated in Figure 5, the conduits or channels defined by the different cooling elements can be substantially parallel to each other along their respective lengths.

[0057] As shown in Figure 6, the multi-pipe cooling element 300 can also be coupled to plate 400 or another structure by coupling the contact surface 312 of the intermediate portion 306 to plate 400 or another structure. In this embodiment, a slot or opening 506 can be formed in plate 400 or structure (e.g., equipment, furnace wall, etc.) at the location of the intermediate portion 306. As a result, a weld or other coupling mechanism can be used to couple the intermediate portion 306 of the cooling element 300 to plate 400. In Figure 6, a plurality of slots or openings 506 can be formed in Petition 870260048552, dated 05 / 21 / 2026, p. 33 / 52 / 25 plate 400 so that access to the contact surface 312 is available. In one example, the contact surface 312 can be welded to plate 400 by means of one or more slots 506. Each slot 506 or opening can be spaced longitudinally and aligned with the contact surface 312 of the intermediate portion 306. Secure welding of the slots or openings 506 can ensure that refrigerant does not leak through the slot or opening 506, nor does refrigerant leak from a conduit 408 to an adjacent conduit 410.

[0058] The plate 400 or other structure may be designed and / or manufactured to include a plurality of slots or openings 506 formed therein and corresponding to the number of intermediate portions 306 provided in a cooling element 300 to be mounted thereon. Thus, the installation process or mounting method of a cooling element 300 on the plate 400 may include forming a desired number of slots in the plate based on the size and number of intermediate portions 306 provided in the cooling element 300. Furthermore, each end 308, 310 of the cooling element 300 may be mounted on the mounting surface 402 of the plate 400 by means of welding or other desired process. In addition, each intermediate portion 306 may be coupled by means of welding or other process to the plate 400 by means of each slot or opening 506.

[0059] With the slots or openings, the amount of welding can be reduced to mount the cooling element 300 on the plate 400, particularly when compared to mounting two or more of the single half-pipe cooling elements 200 on the same plate. Each single half-pipe cooling element 200 requires a tight weld applied to each end, and the result is only a single channel or conduit 406 through which a coolant can flow. On the other hand, a multiple half-pipe cooling element 300 may only include welds along each end and then on each Petition 870260048552, dated 05 / 21 / 2026, page 34 / 52 / 25 slit or opening 506. The result, however, is that you achieve a plurality of channels or conduits.

[0060] Although the description has been illustrated and described in detail in the previous drawings and descriptions, it should be considered as illustrative and not restrictive in nature, it being understood that only illustrative embodiments thereof have been shown and described and that all alterations and modifications that are within the spirit of the description should be protected. Petition 870260048552, dated 05 / 21 / 2026, page 35 / 52

Claims

1 / 3 CLAIMS 1. Cooling assembly for cooling exhaust gases emitted from a steelmaking furnace, characterized in that it comprises: a plate configured to be coupled to the furnace, the plate having a first surface and a second surface, the first surface being opposite the second surface; a body comprising a defined length and a cross-sectional shape having a defined thickness between an outer surface and an inner surface thereof, the body including a first mounting end and a second mounting end; wherein the first mounting end is mounted on the first surface at a first angle greater than 0°; wherein the second mounting end is mounted on the first surface at a second angle greater than 0°, the second mounting end spaced from the first mounting end;where a conduit is defined between the inner surface and the first surface for a cooling fluid to flow through it.

2. Cooling assembly according to claim 1, characterized in that the first angle is approximately the same as the second angle.

3. Cooling assembly according to claim 1 or 2, characterized in that the first angle is different from the second angle.

4. Cooling assembly according to any one of claims 1 to 3, characterized in that the first angle and the second angle are each between 15° and 45°.

5. Cooling assembly according to any of claims 1 to 4, characterized in that it further comprises a second body comprising a definite length and a cross-sectional shape having a definite thickness between an outer surface and an inner surface thereof, the second body including a first mounting end and a second mounting end; wherein the first mounting end of the second body is mounted at an angle to the first surface at a location adjacent to the second mounting end of the body; wherein the body and the second body are mounted to the first surface such that their respective lengths are parallel to each other.

6. Cooling assembly according to claim 5, characterized in that the body and the second body are welded to the first surface such that a single weld is disposed between the angled ends of the first mounting end of the second body, the second mounting end of the body, and the first surface.

7. Cooling assembly according to any one of claims 1 to 6, characterized in that the body is formed from steel, iron, nickel or an aluminum bronze alloy.

8. Heat exchange system, characterized in that it comprises: a furnace having means for heating a furnace interior and generating hot exhaust gases; a winding pipe panel having an inlet and an outlet, the pipe forming a fluid passage through which a cooling fluid flows between the inlet and the outlet; an inlet manifold in fluid communication with the inlet of the panel; an outlet manifold in fluid communication with the outlet of the panel; the pipe comprising a body configured to be coupled to a mounting surface of the furnace, the body comprising a defined length and a cross-sectional shape having a defined thickness between an outer surface and an inner surface thereof, the body including a first mounting end and a second mounting end;wherein the body comprises a first portion, a second portion, and an intermediate portion formed integrally between the first and second portions; wherein the first mounting end is formed integrally in the first portion, the first mounting end comprising a first end surface that is angularly coupled to the mounting surface; wherein the second mounting end is formed integrally in the second portion, the second mounting end comprising a second end surface that is angularly coupled to the mounting surface at a spaced location from the first mounting end; wherein a first fluid conduit is defined between the inner surface of the first portion and the mounting surface, the first fluid conduit forming a portion of the fluid passage;wherein a second fluid conduit is defined between the inner surface of the second portion and the mounting surface, the second fluid conduit forming another portion of the fluid passage. Petition 870260048552, dated 05 / 21 / 2026, pp. 38 / 52;

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