Fluid-Cooled Copper Burner Block for Refractory Erosion Control
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Solution Overview
Problem
Existing burner arrangements in metallurgical furnaces face issues with refractory material deterioration due to thermal stresses and erosion, leading to potential water-gas explosions and prolonged maintenance downtimes, as well as flame misdirection and damage to cooling coils.
Innovation Solution
A burner arrangement featuring a fluid-cooled copper block with a cooling conduit, where the burner unit is releasably attached to one end and the burner channel extends inside the block, providing protection and allowing for easy maintenance, and a tubular mounting sleeve with anchor elements for secure anchoring within a castable refractory structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cooling coil is provided inside the refractory material defining the burner channel, then the durability of the burner channel is improved, but the cooling coil may be damaged due to refractory deterioration leading to water-gas explosion risk
Solution Approach 1:
The patent introduces a metal protective sleeve (intermediary) between the refractory burner channel and the cooling coil. This sleeve acts as a mediator that protects the cooling coil from damage caused by refractory deterioration, erosion, and thermal stresses, while still allowing the cooling function to operate effectively.
Solution Approach 2:
The patent employs a composite structure combining refractory material for the burner channel, a metal protective sleeve for durability, and cooling coil for thermal management. This multi-material composite approach leverages the strengths of each material: refractory for heat resistance, metal for mechanical protection, and cooled surfaces for thermal control.
2Reliability
If the burner unit is installed in a fluid-cooled mounting block without a burner channel in close proximity, then the mounting block provides cooling, but the burner unit may get damaged due to flame blow-back
Solution Approach 1:
The patent merges the cooling function and flame protection function into a single integrated burner channel structure. The burner channel serves dual purposes: guiding the flame in the correct direction and protecting the burner unit from flame blow-back, while the fluid-cooled mounting block provides thermal management.
Solution Approach 2:
The burner channel is designed to perform multiple functions simultaneously: it guides the flame, protects the burner unit from blow-back, and works in conjunction with the fluid-cooled mounting block for thermal management. This multi-functional design eliminates the need for separate protective structures.
3Ease of manufacture
If the burner unit is attached directly to the wall of the gas channel with refractory material, then the installation is simple, but the attachment may loosen due to refractory cracking from thermal stresses and erosion
Solution Approach 1:
The patent uses a composite construction where the burner unit is attached to a fluid-cooled mounting block (metal) rather than directly to refractory material. This combines the ease of metal attachment with the thermal protection of the refractory burner channel, preventing attachment loosening due to refractory cracking.
4Reliability
If a supporting structure is fitted as part of the gas channel wall to support the burner unit, then the burner is supported, but replacement requires interrupting the sintering process causing long downtime
Solution Approach 1:
The patent segments the burner assembly into a removable fluid-cooled mounting block that can be independently replaced. This allows maintenance of the burner unit without interrupting the sintering process, as the mounting block can be quickly swapped out while the refractory structure remains in place.
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
This configuration enhances the durability of the burner channel, prevents damage to the cooling conduit, reduces maintenance downtime, ensures optimal flame direction, and protects the burner unit from erosion and flame blow-back, while allowing for efficient replacement of components without interrupting the sintering process.
Implementation Method 1
a fluid cooled copper block, preferably a water cooled copper block, including a cooling conduit for circulation of the cooling fluid, preferably water
Implementation Method 2
A burner is a device to generate a flame to heat up material by combustion of gaseous, liquid or pulverous fuel
Data Source
AI summary
The invention relates to a burner arrangement comprising a fluid cooled copper block. Further, the invention relates to a burner assembly, a duct element, a gas circulating duct, and a metallurgical furnace comprising said burner arrangement. The burner arrangement (B) comprises a fluid cooled copper block (3) including a cooling conduit (4) for circulation of the cooling fluid, a first end (5) to which the burner unit (1) is releasably attached and a second end (6), and that the burner channel (2) extends inside the fluid cooled copper block (3) from the first end (5) to the second end (6).