Cooled Copper Sill Device for Metallurgical Furnace Slag Door
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional graphite and copper sill devices for metallurgical furnaces deteriorate rapidly due to aggressive molten slag, requiring frequent replacements and disrupting furnace operations.
Innovation Solution
A sill device made of copper or copper alloy with an integrated hydraulic cooling system, featuring a cylindrical base body with annularly arranged cooling ducts and a collection cavity for efficient heat dissipation, allowing the device to maintain a constant contact area with slag and extend its lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a graphite sill device is used, then the device can withstand high temperatures, but it deteriorates rapidly due to aggressive molten slag requiring frequent replacements
Solution Approach 1:
The invention uses a composite structure combining copper base material with a ceramic coating layer. The copper provides thermal conductivity and structural integrity at high temperatures, while the ceramic coating resists erosion from molten slag. This composite approach resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The ceramic coating acts as an intermediary layer between the copper sill device and the aggressive molten slag. This protective barrier allows the copper to withstand high temperatures while the ceramic layer absorbs and resists the erosive effects of the slag, preventing direct contact between the metal and molten material.
2Duration of action of stationary object
If a copper sill device with liquid cooling is used, then the lifespan is improved compared to graphite, but it still shows wear over time and requires replacement
Solution Approach 1:
The copper ceramic composite structure provides both the thermal management capabilities of copper and the wear resistance of ceramic materials. This combination significantly extends the lifespan and reliability of the sill device compared to pure copper, as the ceramic layer protects against wear and chemical degradation.
Solution Approach 2:
The integrated liquid cooling system uses hydraulic flow to remove heat from the copper base material, maintaining lower operating temperatures that reduce thermal stress and wear. The cooling channels distribute coolant throughout the structure to prevent localized overheating and extend device lifespan.
3Reliability
If frequent replacements of sill devices are made, then operational reliability is maintained, but production costs increase and furnace operations are disrupted
Solution Approach 1:
The copper ceramic composite construction provides superior durability and resistance to slag erosion compared to traditional materials. This extended service life reduces the frequency of replacements needed, maintaining operational reliability while minimizing disruptions to furnace operations and reducing overall production costs.
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 cooling system enhances the durability and longevity of the sill device by ensuring homogeneous coolant distribution and improved heat exchange, reducing the need for frequent replacements and minimizing production costs.
Implementation Method 1
A sill device made of copper or copper alloy with an integrated hydraulic cooling system, featuring a cylindrical base body with annularly arranged cooling ducts and a collection cavity for efficient heat dissipation
Implementation Method 2
The cooling system enhances the durability and longevity of the sill device by ensuring homogeneous coolant distribution and improved heat exchange
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
A sill device (1) for a slag door in a metallurgical furnace comprises a base metal body (2) extending mainly around a longitudinal axis (X) from one inlet end (21) to one outlet end (22) and a cooling fluid inlet port (IN) in the vicinity of the inlet end (21) and a cooling fluid outlet port (OUT) in the vicinity of the outlet end (22). The base body (2) comprises a collection cavity (27) around which there is a base body wall (28) which at least partially defines the collection cavity (27). Such collection cavity (27) is in fluid communication with the treatment fluid outlet port. Moreover, the base body (2) comprises cooling ducts (23A, 23A', 24A, 24A', 25A, 25A', 23R, 24R, 25R) made in the base body wall (28) and in fluid communication with the cooling fluid inlet port (IN) and with the collection cavity (27).