Multi-pipe heat exchange system for electric arc, metallurgical or smelting furnace and the system

Abstract

A cooling assembly for cooling exhaust gases emitted from a steelmaking furnace includes a plate configured to be coupled to the furnace. The plate has a first surface and an opposite second surface. The assembly includes a cross-sectional shape having a predetermined length and a thickness defined between an outer surface and an inner surface. A body includes a first mounting end and a second mounting end, the first mounting end attached to the first surface at an angle greater than 0°. The second mounting end is also attached to the first surface at an angle greater than 0° and is spaced apart from the first mounting end. A conduit is defined between the inner surface and the first surface for flowing a cooling fluid therethrough.

Description

[Technical Field]

[0001] [Related Applications] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 108,474, filed November 2, 2020, the disclosure of which is incorporated herein by reference in its entirety.

[0002] The present disclosure relates generally to methods and apparatus for extending the operating life of electric arc furnaces, metallurgical furnaces, including metal smelting and refining furnaces. In particular, the present disclosure relates to heat exchange systems used to protect such equipment. [Background technology]

[0003] It is known to use cooling structures to protect equipment used in various steel industry processes. Such equipment may be required to operate under extreme heat flow conditions. Conventional cooling structures typically include multiple hoses or tubes through which water flows, joined together to form the cooling structure. Such conventional hoses may be, for example, cylindrical hoses with an inside diameter ("ID") of 2.5 inches, with a maximum water velocity through the hose of approximately 6-7 feet per second. The high heat flow conditions in which these hoses may operate may make it desirable to have a higher heat transfer coefficient and higher water flow velocity than conventional 2.5-inch ID hoses can deliver. It is also desirable to be able to fabricate the hoses and resulting components from any suitable material and using any manufacturing process appropriate for the material used. Summary of the Invention [Means for solving the problem]

[0004] In one embodiment of the present disclosure, a cooling assembly for cooling exhaust gases emitted from a steelmaking furnace includes a body configured to be coupled to the furnace, the body having a plate having a first surface and an opposing second surface, a predetermined length and a cross-sectional shape having a thickness defined between an outer surface and an inner surface, the body having a first mounting end and a second mounting end, the first mounting end being attached to the first surface at a first angle greater than 0° and the second mounting end being attached to the first surface at a second angle greater than 0°, the second mounting end being spaced from the first mounting end, a conduit being defined between the inner surface and the first surface for a cooling fluid to flow therethrough.

[0005] In this embodiment, the first angle may be substantially the same as 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°. The assembly may further include a second body having a defined length and a cross-sectional shape with a defined thickness between an outer surface and an inner surface, the second body including a first mounting end and a second mounting end, the first mounting end of the second body being attached to the first surface at an angle adjacent the second mounting end of the second body, and the first body and the second body being attached to the first surface such that their longitudinal directions are parallel to each other.

[0006] In this embodiment, the main body and the second main body may be welded to the first surface such that a single weld is provided between the first mounting end of the second main body, the angled end of the second mounting end of the main body, and the first surface. Further, the main body may be formed from steel, iron, nickel, or an aluminum-bronze alloy.

[0007] In another embodiment of the present disclosure, a cooling assembly for cooling exhaust gases discharged from a steelmaking furnace includes a body configured to be coupled to a mounting surface of the furnace, the body having a predetermined length and a cross-sectional shape with a defined thickness between an outer surface and an inner surface, the body having a first mounting end and a second mounting end, the body having a first portion, a second portion, and an intermediate portion integrally formed between the first portion and the second portion, the first mounting end being integrally formed with the first portion and having a first end face angledly coupled to the mounting surface, the second mounting end being integrally formed with the second portion and having a second end face angledly coupled to the mounting surface at a position spaced from the first mounting end, a first fluid conduit defined between the inner surface of the first portion and the mounting surface, and a second fluid conduit defined between the inner surface of the second portion and the mounting surface.

[0008] In this embodiment, the intermediate portion may include a defined width between the first portion and the second portion, the intermediate portion having a substantially flat surface disposed in contact with the mounting surface across the defined width. Further, the first portion may contact the mounting surface at a first contact point and the second portion may contact the mounting surface at a second contact point, the first contact point and the second contact point each being a single contact point anywhere along the length of the body. Further, the first portion may contact the mounting surface at a first contact point and the second portion may contact the mounting surface at a second contact point, the intermediate portion may contact the mounting surface along its width, the contact between the intermediate portion and the mounting surface being greater than the combined contact between the first portion and the second portion and the mounting surface.

[0009] In this embodiment, the body may be formed from steel, iron, nickel, or an aluminum bronze alloy.

[0010] In addition, in this embodiment, the mounting surface may be formed from a plate having a specified length, width, and thickness, the plate including an opening formed therein, and the main body may be joined to the mounting surface so that the intermediate portion is aligned with the opening in the plate.

[0011] The device may further comprise a coupling mechanism for coupling the intermediate portion to the plate at the opening, hi one aspect, the coupling mechanism comprises a weld.

[0012] In this embodiment, a first weld may be provided between the first mounting end and the mounting surface, and a second weld may be provided between the second mounting end and the mounting surface.

[0013] Further, in this embodiment, the cooling assembly may include a second body having a defined length and a cross-sectional shape with a defined thickness between an outer surface and an inner surface, 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, the third conduit being aligned substantially parallel to the first conduit and the second conduit.

[0014] Furthermore, in this embodiment, the second mounting end of the body may be coupled to the mounting surface proximate the first mounting end of the second body, and a single weld may 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 disclosure, a heat exchange system includes a furnace having means for heating an interior thereof and generating hot exhaust gases; a panel of tortuous and serpentine piping having an inlet and an outlet, the panel forming a fluid passageway for a cooling fluid to flow between the inlet and the outlet; an inlet manifold in fluid communication with the inlet of the panel; and an outlet manifold in fluid communication with the outlet of the panel, the piping having a body configured to be coupled to a mounting surface of the furnace, the body having a predetermined length and a cross-sectional shape with a defined thickness between an outer surface and an inner surface, the body including a first mounting end and a second mounting end, the body having a first portion, a second portion, a third portion, a fourth portion, a fifth portion, a fifth portion, a sixth ... sixth portion, a fifth portion, a sixth portion, a sixth portion, a fifth portion, a sixth portion, a sixth portion, a sixth portion, a fifth portion, a sixth portion, a sixth portion, a sixth portion, a fifth portion, a sixth portion, a sixth portion, a sixth portion, a fifth portion, a sixth portion, a sixth portion, a sixth portion, a fifth portion, a sixth portion, a sixth portion, a and an intermediate portion integrally formed between the first portion and the second portion, wherein the first mounting end is integrally formed with the first portion, the first mounting end having a first end face angledly coupled to the mounting surface, and a second mounting end is integrally formed with the second portion, the second mounting end having a second end face spaced from the first mounting end and angledly coupled to the mounting surface, a first fluid conduit defined between the inner surface of the first portion and the mounting surface, the first fluid conduit forming a portion of the fluid passage, and a second fluid conduit 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 explanation of the drawings]

[0016] [Figure 1] FIG. 1 illustrates a flow diagram of the melting process in a metallurgical furnace. [Figure 2] FIG. 2 illustrates a single half-pipe cooling configuration. [Figure 3] FIG. 3 illustrates a dual half-pipe cooling configuration. [Figure 4] FIG. 4 illustrates a perspective view of a combined single and double half-tube cooling assembly. [Figure 5] FIG. 5 illustrates a front view of the assembly of FIG. [Figure 6] FIG. 6 illustrates a bottom front perspective view of the assembly of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0017] In an electric arc furnace (EAF), the area above the hearth or smelting zone must be protected from the high temperatures of the furnace. The walls, shroud or roof, and ductwork of the EAF vessel are particularly at risk from the enormous thermal, chemical, and mechanical stresses induced by the steel charge. Such stresses severely limit the operating life of the furnace. EAFs are generally designed and fabricated as welded steel structures protected from the high temperatures inside the furnace vessel by refractory linings and water-cooled panels. The water-cooled roof and sidewall panels are located in the portion of the furnace vessel above the melting / smelting zone of the furnace.

[0018] Additionally, furnace exhaust gas ducts are constructed with multiple pipe runs around the perimeter to protect the ductwork from the high temperatures and caustic gases generated during furnace operation. Existing water-cooled panels and ducts are made from various grades and types of plate and tube. The use of water-cooled panels reduces refractory costs and allows steelmakers to operate each furnace at a higher number of heat cycles and at higher electrical and chemical energy inputs. Such panels incorporate multiple tubes in a serpentine configuration and are designed to hang on the interior wall of an electric arc furnace above the hearth, thereby creating a cooling surface between the interior and the furnace wall.

[0019] It is important to maintain a layer of slag on the hot side of water-cooled panels to protect them from degradation due to heat and arcing during normal furnace operation. Slag cups, slag bars, slag pins, and specially designed protruding lines with splines on the hot side of the lines can be used to retain the slag splatted on the hot side of the panels. The slag solidifies on the lines and forms an insulating barrier between the molten ferrous material and the cooling lines, which in turn form the walls of the furnace.

[0020] Referring to FIG. 1 , one embodiment of a furnace is illustrated as an electric furnace type furnace 180. While an EAF is disclosed as an example, it is understood that the principles and teachings of the present disclosure can be readily applied to a basic oxygen furnace (BOF), etc. In FIG. 1 , the EAF 180 can include a furnace shell 112, a plurality of electrodes 114, an exhaust system 116, a cab 118, a rocker tilt mechanism 120, a tilt cylinder 122, and an exhaust gas chamber. The furnace shell 112 can be movably disposed on the rocker tilt mechanism 120 or other tilt mechanism. Furthermore, the rocker tilt 120 can be powered by the tilt cylinder 122. The rocker tilt 120 can also be fixed on the cab 118.

[0021] The furnace shell 112 may include a dish-shaped hearth 124, a generally cylindrical sidewall 126, a spout 128, a spout door 130, and a generally cylindrical circular ceiling 132. The spout 128 and spout door 130 are located on one side of the cylindrical sidewall 126. In the open position, the spout 128 allows introduced air 134 to enter the hearth 124, allowing for the partial combustion of gases 136 produced during refining. The hearth 124 is formed of a suitable high-melting-point material. One end of the hearth 124 is provided with a pouring box, the lower end of which is provided with a tapping means 138. During melting operations, the tapping means 138 is closed by a refractory plug or a slidable gate. The furnace shell 112 is then tilted, the tapping means 138 is unplugged or opened, and molten metal is poured into a pouring ladle, tundish, or other device, as desired.

[0022] Water-cooled panels 140 of winding and meandering piping 150 may be attached to the interior walls 126 of the furnace shell 112. The panels, in effect, function as the interior walls of the furnace 180. Cooling water supply and return manifolds are in fluid communication with the panels 140. Typically, the manifolds are arranged around the periphery in a configuration similar to the illustrated exhaust ducts 144.

[0023] The heat exchange system 110 results in more efficient operation and extends the operating life of the EAF furnace 110. In an exemplary embodiment, the panels 140 may be assembled such that the winding and meandering piping have a generally horizontal orientation. The piping 150 may have a base that is coupled with a coupling member or attached to a wall. Alternatively, the panels 140 may be mounted such that the winding and meandering piping 150 have a generally vertical orientation. The upper ends of the panels 140 may define a circular edge at the upper edge of the sidewall 126 of the furnace 180.

[0024] The heat exchange system 110 can be fitted to the ceiling 132 of the furnace 180, with the water-cooled panels 140 having a curvature that substantially follows the dome-shaped contour of the ceiling 132. The heat exchange system 110 can also be disposed inside the sidewalls 126 of the furnace 180, on the ceiling 132, and on the entrance to and throughout the exhaust system 116. In that way, the heat exchange system 110 can protect the furnace and cool the hot exhaust gases 136 as they are ducted to a dust collector or other filter and air treatment facility that collects dust and releases the gases to the atmosphere.

[0025] During operation, hot exhaust gases 136, including dust and fumes, are removed from the hearth 124 through vents 146 in the furnace shell 112. The vents 146 may be in communication with an exhaust system.

[0026] The panel 140 can have multiple axially arranged pipes 150. U-shaped elbows can connect adjacent pipes or longitudinal sections of pipe 150 to each other to form a continuous piping system. Joints or the like can be present between adjacent pipes 150, additionally functioning as spacers, providing structural integrity to the panel 140 and determining the curvature of the panel 140.

[0027] The heat exchange system or heat exchanger 110 can include at least one panel of tortuous and winding piping 150 having inlets (not shown) and outlets (not shown), an inlet manifold in fluid communication with the inlets of at least one panel, an outlet manifold in fluid communication with the outlets of at least one panel, and a cooling fluid flowing through the piping 150. The heat exchange system 110 cools hot fume gases 136 and dust exhausted from a metallurgical furnace 180 and its supporting components. The piping is a collection of connected tubular longitudinal sections mounted side-by-side, the connected tubular sections secured together using a joining mechanism that forms at least one panel 150.

[0028] One exemplary and desirable construction for fabricating the piping 150 has been determined to be aluminum-bronze alloy. Aluminum-bronze alloys have been found to have higher than expected thermal conductivity, resistance to etching by high-temperature gas streams (elastic modulus), and good resistance to oxidation, thereby extending the operating life of the heat exchanger. When fabricated from aluminum-bronze, corrosion and erosion of the heat exchanger and associated components is reduced. Aluminum-bronze has a thermal conductivity 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 fabricated using aluminum-bronze and its alloys are more efficient and have longer operating lives than furnaces constructed from refractive materials and / or other metal alloys.

[0029] Additionally, the piping 150 may be protruding, and it has been determined that such protrusions may help the piping resist corrosion, erosion, pressure, and thermal stresses. The piping may be bent or curved as needed to match the curvature of the wall to which it is attached. More typically, the individual sections of piping are secured together with angled joints so that the resulting panel has a curvature that corresponds to the curvature of the wall.

[0030] 1, the winding piping 150 may be formed by multiple longitudinal piping sections, with two piping sections connected by elbows. While assembling these sections into elbows is often difficult, the present disclosure provides an arrangement to facilitate and improve the welding process.

[0031] Illustratively, in accordance with the present disclosure, a high heat flux tolerant fluid-cooled component is provided, having a relatively high heat transfer coefficient and high water velocity. It will be understood that the component may have any suitable fluid, such as, for example, a liquid including water, flowing therethrough. The present disclosure provides a broader range of material selection methods for the fabrication of user-selected shapes and designs of water-cooled components for steel industry applications. As previously mentioned, liquids or coolants other than water are also within the scope of the present disclosure. The component will be better able to withstand the harsh and ever-changing demands of furnaces, smoke ducts, flue gas hoods, skirts, combustion chambers, dropout boxes, and the like, due to the inherent and improved coolant velocity within the tube / component and the resulting increased heat transfer capacity. The present disclosure is not limited to current requirements for selecting tubes / tubes from commercially available materials, but allows for the selection of manufacturing materials and manufacturing methods, including, for example, by rolling, forging, casting, or extrusion, to achieve the necessary or desired cross-sectional radius, as desired, to optimize heat transfer and resilience requirements for a particular application.

[0032] Referring to FIG. 2 , a cooling structure 200 or heat exchanger in the form of a single half-tube 202 or semi-cylindrical tube 202 is formed into a desired shape, such as a half-tube 202 having a substantially semicircular or polygonal cross-section, including a quadrilateral, parallelogram, hexagon, or octagon. In other words, the half-tube 202 may illustratively approximate a polyhedron or cylinder substantially bisected along its diametric plane to form a semi-polyhedron, as described below, or the illustrative semi-cylinder 202 shown. The illustrative bisected or semi-cylindrical body or half-tube 202 extends from a first mounting end 204 to a second and opposing mounting end 206, defining an arcuate, generally concave inner surface 208 and an arcuate, generally convex outer surface 210 between the mounting ends 204, 206, respectively. In other words, the single cylindrical tube or half-tube 202 represents one half of a cylindrical body bisected or substantially bisected diametrically.

[0033] The opposing mounting ends 204, 206 are illustratively configured to mount or couple the single half-tube 202 to a mounting plate 400, for example, as shown in FIG. 4 . It will be appreciated that the single half-tube 202 may be mounted directly to a body of equipment, such as the wall of the furnace 180. In FIG. 4 , the single half-tube 202 is shown mounted or coupled to a tube mounting surface 402 of the mounting plate 400 to form the illustrative cooling structure 200. The single half-tube 202 may include a specified length L, which may be selected based on desired heat transfer characteristics and the space available for the tube. Opposite the tube mounting surface 402 of the mounting plate 400 is an equipment mounting surface 404 illustratively configured to mount the plate 400 to a body of equipment.

[0034] The single half-tube 202 may be attached or coupled to the plate 400 in any suitable manner, including, for example, by welding along the length of the tube 202 at each side or its attachment ends 204, 206. For example, as shown in FIG. 5 , the single half-tube 202 may be attached via a first weld 500 along its first end 204 and a second weld 502 along its second end 206. Each of the first and second welds may be watertight welds that protect the integrity of the tube 202 and prevent leakage of fluids that may flow through the internal passages or channels 406 of the single half-tube 202.

[0035] As shown in FIG. 2 , each mounting end 204, 206 may be angled relative to the bisecting surface (i.e., the dashed line in FIG. 2 ) or plate 400. In one example, mounting ends 204, 206 may include an angle Θ greater than 0°. In one non-limiting example, angle Θ may be greater than 0° but less than 90°. In a second non-limiting example, angle Θ may be greater than 0° and less than 75°. In a third non-limiting example, angle Θ may be greater than 0° and less than 60°. In a fourth non-limiting example, angle Θ may be greater than 0° and less than 45°. In a fifth non-limiting example, angle Θ may be greater than 15° and less than 45°. In a sixth non-limiting example, angle Θ may be greater than 30° and less than 45°. In a further non-limiting example, angle Θ may be approximately 30-40°, but is defined to within approximately 2-3°.

[0036] The angled mounting ends allow each mounting end to contact the surface 402 of the mounting plate 400 or the furnace wall at a single point at that end in the cross-sectional view of Figure 2. If the mounting end has approximately the same length as the entire half-tube cooling arrangement 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 can be positioned between the top surface of the mounting surface of the plate 400 or wall and at least a portion of the bottom surface of each mounting end 204, 206. This further enables a watertight seal therebetween to prevent or reduce leakage of cooling fluid flowing through the cooling structure or half-tube. Additionally, each mounting end is more reliably held to the mounting surface with a stronger weld than if the bottom surface of the mounting end were flush with the mounting surface.

[0038] Any single half-pipe attachment end 204, 206 may illustratively and optionally have an extension or tab (not shown). For example, if the attachment ends 204, 206 of adjacent pipes have tabs or radially extending portions, welding can be used to attach or bond the respective ends 204, 206 along their lengths to the plate 400 or to a member of the equipment body.

[0039] When the single half-tube 202 and the plate 400 are joined together, a flow path 406 is formed, configured to contain and allow a fluid, including, but not limited to, any suitable coolant, such as a liquid, to pass therethrough. One non-exclusive example of a suitable liquid is water. The conduit or flow path 406 can also be formed by directly attaching the single half-tube 202 and the fixture body together. It should also be understood that the conduit or flow path 406 can be formed by forming a closed conduit 202 having a generally flat surface extending between the attachment ends 204, 206 along a diametrical plane. Such an exemplary surface need not be flat or planar and can be attached to the plate 400 or directly to the fixture body.

[0040] The single half-tube 202 may include several dimensions, including, but not limited to, an inside diameter, which represents the length of the radial surface extending between the mounting ends 204, 206. As a result, the inner radius 212 and outer radius 214 represent the length of the surface between the midpoint of the radial surface and any point on the respective inner surface 208 and outer surface 210. These dimensions may be selected as needed.

[0041] Referring to FIG. 3 , another embodiment of a cooling structure is shown. Here, the cooling structure is depicted in the form of a double half-tube 300 or a cylindrical tube. The double half-tube 300 may be manufactured as a pair of single half-tubes 202, or may be manufactured as a single unit. The double half-tube 300 in FIG. 3 is shown having a first half-tube section 302 and a second half-tube section 304. The first and second sections may be formed into any desired shape, such as having a cross-section that substantially approximates a semicircle or polygon, including a quadrilateral, parallelogram, hexagon, or octagon. In other words, each section may substantially approximate a polyhedron or cylinder bisected along its diametric plane to form a half-polyhedron, as described below, or the exemplary half-cylinders 302, 304 shown.

[0042] The first and second half-tube sections 302, 304 may be integrally formed with a third or intermediate section 306 defined therebetween. The intermediate section 306 may have a substantially flat surface 312 or interface where it may be attached to a plate 400 or other equipment. The intermediate section 306 may have a defined width or spacing d between the first and second tube sections, as shown in FIG.

[0043] In the illustrated embodiment of the present disclosure, the dual half-tube cooling structure 300 is shown with only one pair of half-tubes and a single intermediate portion integrally formed therebetween. However, the present disclosure is not limited to this configuration. Instead, the cooling structure can have two or more half-tubes with respective intermediate portions formed between each pair of half-tubes. Thus, in one embodiment, the cooling structure may include three half-tubes and a pair of intermediate portions integrally formed between each of the two pairs of half-tubes. In a further embodiment, the cooling structure may include four half-tubes and three intermediate portions integrally formed between two of the four half-tubes. In yet another embodiment, the cooling structure may include X half-tubes and Y intermediate portions, where X is greater than or equal to 2 and Y is equal to X−1.

[0044] The exemplary bisecting or semi-cylinder or half-tube sections 302, 304 may extend from a first mounting end 308 to a second and opposing mounting end 310 and define an arcuate and generally concave inner surface 318 and an arcuate and generally convex outer surface 320 between the mounting ends 308, 310, respectively. The distance between the mounting ends 308, 310 may be further defined as the sum of the inside diameter of the first half-tube section 302, the inside diameter of the second half-tube section 302, and the width or distance d of the intermediate portion 306.

[0045] Each half-tube section of the cooling structure may include several dimensions, including an inner radius 314 and an outer radius 316, which respectively represent the length of the surface between the midpoint of the radial surface and any point on the respective inner and outer surfaces 318 and 320. These dimensions may be selected as needed. The thickness of each half-tube section may be defined as the difference between the inner and outer diameters or the difference between the inner and outer surfaces. In one embodiment, the thickness of each section may be uniform. In another example, the thickness may vary from one end to the other. In a further embodiment, the thickness of a half-tube section may be the same as the thickness of the intermediate section. In other words, the thickness of the intermediate section may be approximately the same as the difference between the outer radius 316 and the inner radius 318. This difference in radius may be uniform between the first end 308 and the second end 310. In an alternative embodiment, the difference between the outer and inner radius of the first half-tube section 302 may be different from the difference between the outer and inner radius of the second half-tube section 304.

[0046] As shown in FIG. 3 , each mounting edge 308, 310 may be angled relative to the bisecting surface (i.e., the dashed line in FIG. 3 ) or plate 400. In one example, mounting edges 308, 310 may include an angle Θ2 greater than 0°. In one non-limiting example, angle Θ2 may be greater than 0° but less than 90°. In a second non-limiting example, angle Θ2 may be greater than 0° and less than 75°. In a third non-limiting example, angle Θ2 may be greater than 0° and less than 60°. In a fourth non-limiting example, angle Θ2 may be greater than 0° and less than 45°. In a fifth non-limiting example, angle Θ2 may be greater than 15° and less than 45°. In a sixth non-limiting example, angle Θ2 may be greater than 30° and less than 45°. In a further non-limiting example, angle Θ2 may be approximately 30-40°, but is defined to within approximately 2-3°. In one embodiment, the angle of first mounting end 308 may be approximately the same as the angle of second mounting end 310, but within approximately 2-3°. In other embodiments, the angle of first mounting end 308 may be substantially different from the angle of second mounting end 310, but the difference is greater than 3 degrees.

[0047] With the angled mounting ends, each mounting end 308, 310 may contact the surface 402 of the mounting plate 400 or the furnace wall at a single point on that end in the cross-sectional view of FIG. 3 . For example, the first mounting end 308 may contact the surface 402 at a first contact point 324, and the second mounting end 310 may contact the surface 402 at a second contact point 326, but the first and second contact points are spaced apart. The first mounting end 308 may have a first end surface 322 that contacts the surface 402 at the first contact point 324, but the remainder of the first end surface 322 may not contact the surface 402. Similarly, the second mounting end 310 may have a second end surface 328 that contacts the surface 402 at a second contact point 326, but the remainder of the second end surface 328 may not contact the surface 402. If the mounting end has approximately the same length as the entire half-tube cooling arrangement 300, the mounting end may contact the surface at this point along the entire length of the mounting end.

[0048] With the mounting ends 308, 310 angled, the first weld 508 and the second weld 510 can be positioned between the top surface 402 of the plate 400 or wall-and-furnace mounting surface and at least a portion of the bottom surface 322, 328 of each mounting end 308, 310. This further provides a watertight seal therebetween to prevent or reduce leakage of cooling fluid flowing through the cooling structure or half-tube. Additionally, each mounting end is more reliably held to the mounting surface with stronger welds than if the bottom surface of the mounting end were flush with the mounting surface.

[0049] In FIG. 3 , the dual half-tube 300 can be selectively fabricated 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 alloys, and any other suitable element, composition, or alloy, such as aluminum bronze. Additionally, the material selection for the tube 300 or cylindrical tube can be selected from a wider range of flat or formed materials, which can be rolled, forged, or extruded into the desired semicircular cross section or semicylindrical shape, thereby improving the operational performance of the cooling component compared to prior art circular cylindrical tubes and cooling components formed therefrom. The higher heat transfer of the present disclosure can have the effect of improving equipment life, plus online reliability and uptime, because the equipment is better suited to withstand the effects of high heat flux, corrosive, and abrasive atmospheres within furnaces, smoke exhaust systems, or combustion chambers, and any other equipment protected by one or more assemblies of such components.

[0050] In one embodiment of the present disclosure, a method for manufacturing a multi-half-tube cooling structure is provided, wherein a length of bar material (with the material being selected based on application requirements known to those skilled in the art) may be rolled, formed, cast, or extruded into one or more desired arcs along its length to meet the cross-sectional area requirements of the cooling structure. The material may be selectively fabricated 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 alloys), and any other suitable element, composition, or alloy, such as aluminum bronze.

[0051] The material may be selected to be substantially flat for the manufacturing process. Intermediate sections between each arc or half section may be formed simultaneously during this manufacturing process. The cross-sectional area may be tailored to meet the desired coolant velocity, pressure drop, and residence time in the cooling structure needed to optimize the operating life of the cooling structure.

[0052] In this embodiment, the entire length of the bar can have a substantially constant geometry throughout its length. Each rolled, formed, cast, or extruded arc, or half, generally spans an approximately 180-degree arc from end to end, simulating a multiple half-tube / tube arrangement. The resulting arc can also be designed with edges or wings at its opposing ends to allow multiple tubes to be welded together. The exterior surface can be generally smooth or can incorporate geometries as required for a particular application, such as ridges, splines, heat sinks, or optional slug retention elements, including optional recesses. A dual or multiple half-tube cooling structure 300, as shown in FIG. 3, can have advantages over the single half-tube cooling structure 200 of FIG. 2 due to its ease of manufacture and can provide better performance by eliminating approximately half of the welds. Notably, the cooling structure 300 of FIG. 3 includes two or more half-tubes fabricated as a single unit, for example, by extrusion or molding. In this manner, manufacturing this type of cooling structure can eliminate approximately 50% of the welding, thereby avoiding all the potential weld defects and failures associated with single half-tube cooling structures.

[0053] Referring to the embodiment of FIG. 4 , the dual half-tube cooling arrangement 300 is shown attached to a plate 400 adjacent to the single half-tube cooling arrangement 200. This type of arrangement is possible in accordance with the teachings of the present disclosure. When attached to the plate 400 or fixture, the first half-tube section 302 defines a conduit or flow channel 410 between its inner surface 318 and the mounting surface 402 of the plate 400. As such, a coolant, such as water, can flow through the conduit or flow channel 410. Similarly, the second half-tube section 304 defines a conduit or flow channel 408 between its inner surface 318 and the mounting surface 402 of the plate 400. Furthermore, the coolant, such as water, can flow through the conduit or flow channel 408 generally parallel to the direction of coolant flow through the other conduits or flow channels 406, 410.

[0054] In alternative embodiments, a system utilizing a single and / or double half-pipe may have a first fluid source (e.g., water) and a second fluid source (e.g., air or other coolant). The system may be designed such that the first fluid source is fluidly coupled to the first flow path 410 and the second fluid source is fluidly coupled to the second flow path 408. Alternatively, a first fluid source is fluidly coupled to each flow path 406 of the single half-pipe 200, and a second fluid source is fluidly coupled to each flow path 408, 410 of the double half-pipe 300. Other arrangements are possible, including the use of non-fluids. For example, in some embodiments, there may be two or more fluid sources, with two or more different fluids passing through various flow paths or conduits to help provide cooling to the furnace.

[0055] 5 and 6 illustrate the assembly of cooling structures. Specifically, they illustrate how a dual or multiple half-tube cooling structure 300 can be attached or otherwise coupled to a mounting plate or other surface (e.g., the wall of a furnace or other facility). Here, for example, a first end 308 can be welded via a first weld 508, and a second end 310 can be welded via a second weld 504. Each weld is preferably watertight to prevent any leakage of the coolant flowing through the half-tube and to prevent any wetting or corrosion of the pipes. While the half-tubes are shown coupled or attached to the plate 400 via welding, it should be understood that other forms of coupling or mounting the cooling structure 300 to the plate 400 are also possible. Depending on the application and environment, the cooling structure 300 can be mechanically coupled via fasteners other than welding, adhesive means, or any other known method. Additionally, adhesive or mechanical fasteners may be used to connect the intermediate portion 306 to the plate 400 or wall, while welding, adhesive or other connecting means may be used to connect the mounting end thereto.

[0056] 5, the single half-tube cooling structure 200 and the dual half-tube cooling structure 300 are shown as being welded to the plate 400 with their own welds, however, in other embodiments, the second weld 502 and the first weld 508 can be a single weld. Additionally, in this exemplary embodiment of FIG. 5, the conduits or flow channels defined by the different cooling structures may be substantially parallel to one another along their respective lengths.

[0057] As shown in FIG. 6 , the multi-semi-tube cooling structure 300 may also be coupled to a plate 400 or other structure by coupling the contact surface 312 of the intermediate portion 306 to the plate 400 or other structure. In this embodiment, a slot or opening 506 may be formed in the plate 400 or structure (e.g., equipment, furnace wall, etc.) at the intermediate portion 306. As a result, welding or other coupling mechanisms may be used to couple the intermediate portion 306 of the cooling structure 300 to the plate 400. In FIG. 6 , multiple slots or openings 506 may be formed in the plate 400 to allow access to the contact surface 312. In one embodiment, the contact surface 312 may be welded to the plate 400 through one or more slots 506. Each slot 506 or opening may be longitudinally spaced and aligned with the contact surface 312 of the intermediate portion 306. A secure weld at the slot or opening 506 can ensure that coolant does not leak through the slot or opening 506 or that coolant does not leak from one line 408 to an adjacent line 410.

[0058] The plate 400 or other structure may be designed and / or manufactured to include a number of slots or openings 506 formed therein that correspond to the number of intermediate portions 306 provided in the cooling structure 300 to be attached. Accordingly, the assembly process or method for attaching the cooling structure 300 to 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 structure 300. Furthermore, each end 308, 310 of the cooling structure 300 may be attached to the mounting surface 402 of the plate 400 via welding or other desired processes. Furthermore, each intermediate portion 306 may be coupled to the plate 400 via each slot or opening 506 by welding or other processes.

[0059] The slots or openings allow for a reduced amount of welding to attach the cooling structure 300 to the plate 400, especially when compared to attaching two or more single half-tube cooling structures 200 to the same plate. Each single half-tube cooling structure 200 requires a watertight weld at each end thereof, resulting in only a single flow channel or conduit 406 through which coolant can flow. In contrast, a multiple half-tube cooling structure 300 need only include a weld along each end and then along each slot or opening 506. However, the result is that multiple flow channels or conduits are achieved.

[0060] While the present disclosure has been illustrated and described in detail in the foregoing drawings and description, the same are to be considered as illustrative and not restrictive, it being understood that only exemplary embodiments have been shown and described, and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.

Claims

1. 1. A cooling assembly for cooling exhaust gases discharged from a steelmaking furnace, comprising: a body configured to be coupled to a mounting surface of the steelmaking furnace, the body having a predetermined length and a cross-sectional shape with a defined thickness between an outer surface and an inner surface, the body including a first mounting end and a second mounting end; the body includes a first portion, a second portion, and an intermediate portion integrally formed between the first portion and the second portion; the first mounting end is integrally formed with the first portion, the first mounting end having a first end surface that is angled to join the mounting surface; a second mounting end integrally formed with the second portion, the second mounting end having a second end surface spaced apart from the first mounting end and angled to the mounting surface; a first fluid conduit defined between the inner surface of the first portion and the mounting surface; A cooling assembly wherein a second fluid conduit is defined between the inner surface of the second portion and the mounting surface.

2. 2. The cooling assembly of claim 1, wherein the intermediate portion has a width defined between the first portion and the second portion, the intermediate portion having a substantially flat surface positioned in contact with the mounting surface across the defined width.

3. the first portion contacts the mounting surface at a first contact point; the second portion contacts the mounting surface at a second contact point; The cooling assembly of claim 1 , wherein the first contact point and the second contact point are each a single contact point anywhere along the length of the body.

4. the first portion contacts the mounting surface at a first contact point; the second portion contacts the mounting surface at a second contact point; 2. The cooling assembly of claim 1, wherein the intermediate portion contacts the mounting surface along a width direction, and the contact between the intermediate portion and the mounting surface is greater than the combined contact between the first portion and the second portion and the mounting surface.

5. The cooling assembly of claim 1 , wherein the body is formed from steel, iron, nickel, or an aluminum-bronze alloy.

6. the mounting surface is formed from a plate having a specified length, width, and thickness, the plate including an opening formed therein; The cooling assembly of claim 1 , wherein the body is coupled to the mounting surface such that the intermediate portion is aligned with the opening in the plate.

7. The cooling assembly of claim 6 , further comprising a coupling mechanism for coupling the intermediate portion to the plate at the opening.

8. The cooling assembly of claim 7 , wherein the coupling mechanism comprises a weld.

9. a first weld disposed between the first mounting end and the mounting surface; a second weld disposed between the second mounting end and the mounting surface; The cooling assembly of claim 8 , further comprising:

10. a second body including a defined length and a cross-sectional shape having a defined thickness between an outer surface and an inner surface, the second body including a first mounting end and a second mounting end; 2. The cooling assembly of claim 1, wherein a third fluid conduit is defined between the inner surface of the second body and the mounting surface, the third fluid conduit being aligned substantially parallel to the first fluid conduit and the second fluid conduit.

11. The cooling assembly of claim 10 , wherein the second mounting end of the body is coupled to the mounting surface adjacent the first mounting end of the second body.

12. The cooling assembly of claim 11 , wherein a single weld joins the second mounting end of the body and the first mounting end of the second body to the mounting surface.

13. a furnace having means for heating the interior thereof and generating hot exhaust gases; a panel of meandering piping having an inlet and an outlet, the panel defining a fluid passageway between the inlet and the outlet for flow of cooling fluid; an inlet manifold in fluid communication with the inlet of the panel; an output manifold in fluid communication with the outlet of the panel; The piping includes a body configured to be coupled to a mounting surface of the furnace, the body comprising: a first attachment end and a second attachment end, the first attachment end having a predetermined length and a cross-sectional shape with a defined thickness between an outer surface and an inner surface; the body includes a first portion, a second portion, and an intermediate portion integrally formed between the first portion and the second portion; the first mounting end is integrally formed with the first portion, the first mounting end having a first end surface that is angled to join the mounting surface; a second mounting end integrally formed with the second portion, the second mounting end having a second end surface spaced apart from the first mounting end and angled to the mounting surface; a first fluid conduit defined between the inner surface of the first portion and the mounting surface, the first fluid conduit forming a part of the fluid passage; a second fluid conduit defined between the inner surface of the second portion and the mounting surface, the second fluid conduit forming another portion of the fluid passageway;

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