Angled Plate Cooler Stave for Blast Furnace Shell Protection
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Solution Overview
Problem
Conventional cooling systems for blast furnaces, such as cooling plates and staves, suffer from non-uniform cooling leading to corrosion issues and require complex installation and maintenance procedures, including the need for multiple protrusions and compensators.
Innovation Solution
A plate cooler stave design that allows for external installation through a single opening, featuring a top portion with cooling fluid inlets and outlets, a main body angled for insertion, and a refractory lining with grooves for bricks, eliminating the need for internal stave removal and reducing the requirement for pins, thermocouple protrusions, and flexible compensators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cooling plates are used, then they can be securely fastened to the steel shell, but they provide non-uniform cooling leading to greater corrosion at distant locations
Solution Approach 1:
The cooling system is divided into multiple cooling staves that can be arranged to provide uniform coverage across the furnace shell surface, replacing the single large cooling plate approach with segmented modular units
Solution Approach 2:
The cooling staves are designed with three-dimensional configurations including protrusions and recesses that allow them to be positioned at various angles and depths against the furnace shell, enabling uniform cooling coverage across complex curved surfaces
2Reliability
If conventional staves are installed with complete steel shell coverage, then uniform cooling is achieved, but complex installation and maintenance procedures are required including multiple protrusions and compensators
Solution Approach 1:
Multiple functions are combined into the cooling stave structure itself, including integrated support features, sealing elements, and alignment mechanisms that eliminate the need for separate pins, thermocouple protrusions, water pipe protrusions, and flexible compensators
Solution Approach 2:
The cooling stave design incorporates universal features that serve multiple purposes: the same structural elements provide both cooling functionality and mechanical support, sealing, and alignment, reducing the overall number of components required
3Reliability
If bricks are placed close to cooling plates, then they are effectively cooled, but those at distance are subject to greater corrosion and non-uniform cooling is achieved
Solution Approach 1:
The cooling stave design allows for localized adjustment of cooling intensity and distribution across different regions of the furnace shell, with the ability to position cooling surfaces at optimal distances from bricks in different zones to achieve uniform cooling throughout
4Ease of repair
If conventional staves require removal to access bricks, then brick replacement is possible, but the staves must be removed from the furnace completely
Solution Approach 1:
The brick lining is extracted as a separate removable component from the cooling stave structure, allowing bricks to be accessed and replaced independently while the cooling stave remains installed on the furnace shell
Solution Approach 2:
The cooling stave structure is pre-configured with accessible channels and openings that allow brick replacement to be performed without removing the stave, preparing the structure in advance to facilitate easy maintenance access
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Provides uniform cooling, reduces corrosion, and simplifies installation and maintenance by allowing external access and secure fastening, enhancing furnace shell protection and operational efficiency.
Implementation Method 1
a plate cooler stave design that allows for external installation through a single opening, featuring a top portion with cooling fluid inlets and outlets
Implementation Method 2
cooling fluid inlets and outlets for the flow of cooling fluid to and from the plate cooler stave
Implementation Method 3
a refractory lining with grooves for bricks
Data Source
AI summary
A plate cooler stave for use in a furnace having a shell wall, comprising: a top portion housing at least one cooling fluid inlet and at least one cooling fluid outlet for the flow of cooling fluid to and from the plate cooler stave from outside the furnace; and a main body disposed at an angle relative to the top portion so that the main body may be inserted into the furnace through an opening defined by the shell wall, wherein upon installation, at least a part of the top portion is disposed in the opening.