Metallurgical Cooling Plate Rib Erosion Protection
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Solution Overview
Problem
Copper cooling plates for metallurgical furnaces experience erosion of lamellar ribs without a refractory protective layer, reducing anchoring power and cooling capacity.
Innovation Solution
Incorporating a metal insert, preferably high wear-resistant steel, into the grooves of the cooling plate to protect the ribs from erosion, maintaining anchoring functionality and extending the plate's lifespan, with the option to replace the insert when damaged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If copper cooling plates are operated without a refractory protective layer, then operational flexibility is improved, but the lamellar ribs suffer erosion reducing anchoring power and cooling capacity
Solution Approach 1:
The patent applies local quality by providing erosion protection only at critical locations where the metal insert is placed in the grooves, rather than covering the entire cooling plate surface. This localized protection maintains anchoring power at the ribs while allowing operational flexibility without a full refractory lining.
Solution Approach 2:
The patent uses composite materials by combining copper (for thermal conductivity and structural integrity) with a metal insert material (for erosion resistance). This composite structure allows the cooling plate to maintain its cooling function while gaining enhanced protection against erosion in specific areas.
2Adaptability or versatility
If copper cooling plates are operated without a refractory protective layer, then operational flexibility is improved, but cooling capacity is reduced due to erosion of lamellar ribs
Solution Approach 1:
The metal insert provides localized erosion protection at the grooves and ribs, preserving the cooling surface integrity and maintaining effective heat transfer areas, thereby sustaining cooling capacity while enabling operation without full refractory lining.
Solution Approach 2:
The metal insert acts as a sacrificial protective element that can be replaced when worn, protecting the more valuable copper cooling plate structure. This allows the system to operate without expensive permanent refractory linings while maintaining cooling performance.
3Reliability
If a metal insert is added to protect the grooves, then erosion resistance is improved, but device complexity increases
Solution Approach 1:
The protection system is segmented into discrete metal inserts placed only in the grooves, rather than a continuous protective layer. This segmentation simplifies installation and replacement while providing targeted protection where it is most needed for erosion resistance.
Solution Approach 2:
The metal insert serves as an intermediary element between the copper cooling plate and the harsh furnace environment. This intermediate protective layer absorbs the erosive effects, protecting the underlying copper structure without requiring direct protection of the entire plate surface.
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
The metal insert significantly reduces rib erosion, maintains anchoring effectiveness, and prolongs the cooling plate's operational life even when operated without a protective layer, ensuring continued heat evacuation and protection.
Implementation Method 1
the metal insert largely prevents material from the rib being removed by the harsh conditions in the furnace
Implementation Method 2
a heat evacuating protection screen between the interior of the furnace and the outer furnace shell
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A cooling plate (10) for a metallurgical furnace in accordance with the present invention has a panel-like body (12) with a front face (14) and an opposite rear face (16), an upper edge (22) and an opposite lower edge (24), and a first side edge (18) and an opposite second side edge (20). The front face (14) is provided with grooves (32) extending between the first and second edges (18, 20), the grooves (32) forming lamellar ribs (34) on the front face (14), each rib (34) having a crest (37) and adjoining sidewalls (39, 39'), a base (38) being arranged in the groove (32) between two neighboring ribs (34). In accordance with an important aspect of the present invention, at least one of the grooves (32) is provided with a metal insert (40) arranged against at least one of the sidewalls (39, 39').