Metallurgical Furnace Burner Panel with Integrated Spray Cooling
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Solution Overview
Problem
Conventional burner panels for metallurgical furnaces require complex and costly maintenance due to their weight, size, and intricate cooling systems, making them difficult and expensive to remove, repair, and replace, especially in the harsh environment of metallurgical furnaces.
Innovation Solution
A burner panel design featuring a copper body with an integral carbon steel frame for welding to the furnace plate, utilizing a non-pressurized spray cooling system that eliminates the need for separate cooling piping, reducing material usage and weight, and allowing for easier mounting and dismounting without external plumbing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional burner panels with internal high-pressure cooling pipes are used, then the burner panel can withstand the heat of the furnace, but the burner panel becomes heavy and difficult to remove, repair, and replace
Solution Approach 1:
The burner panel is divided into multiple segments that can be independently removed and replaced. Each segment contains integrated cooling channels formed directly in the burner panel body rather than requiring separate internal piping systems, allowing for easier maintenance while maintaining heat resistance.
Solution Approach 2:
The cooling system is merged with the burner panel body itself. Cooling channels are formed directly within the burner panel structure, eliminating the need for separate internal high-pressure cooling pipes. This integration reduces weight and simplifies the overall system while maintaining effective heat dissipation.
2Temperature
If conventional burner panels with separate cooling systems are used, then the burner panel can be effectively cooled, but the complexity and cost of maintenance increases
Solution Approach 1:
The cooling system is integrated directly into the burner panel body with cooling channels formed within the panel structure itself. This eliminates the need for separate external cooling piping and systems, reducing overall complexity while maintaining effective cooling performance.
Solution Approach 2:
The burner panel includes self-contained cooling channels that require no external plumbing or separate cooling system infrastructure. The panel cools itself through its integrated channels, and individual segments can be independently removed and replaced without affecting the cooling system of other panels, simplifying maintenance operations.
3Reliability
If burner panels are mechanically fixed in place to seal openings, then the burner panel provides a secure seal, but the assembly and disassembly process becomes labor intensive and time consuming
Solution Approach 1:
The burner panel is segmented into multiple independently removable sections. Each segment can be quickly detached and replaced without requiring the disassembly of the entire panel assembly, significantly reducing maintenance time while maintaining reliable sealing through the segmented design.
Solution Approach 2:
The burner panel incorporates a removable and replaceable segment design that transitions from a fixed, permanent installation to a dynamic, easily reconfigurable system. This allows for quick assembly and disassembly of individual segments while maintaining secure sealing when installed, enabling rapid maintenance operations.
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 design simplifies maintenance by eliminating the need for external cooling systems and reduces the weight and cost of burner panels, enabling quicker and less labor-intensive replacement while maintaining performance under operational conditions.
Implementation Method 1
One cooling method, referred to as non-pressurized spray-cooling, sprays a fluid-based coolant (e.g., water) against an external surface of plate that comprises the roof, sidewall or other hot surface of the furnace
Implementation Method 2
As the fluid-based coolant contacts the external surface of the plate, the plate is relieved of heat transferred to the plate from the molten materials within the furnace
Data Source
AI summary
One or more embodiments of a burner panel for a metallurgical furnace is described herein. The burner panel has a body. The body has a front face, a first side surface, and a second side surface. Additionally, the body has a hollow extending between the first side surface, second side surface, and the front face. A middle portion of the body extends from the hollow toward the interior face. A burner tube is disposed through the middle portion of the body. The burner tube has an exterior portion having an entry and an exit disposed at the font face. An internal mounting flange extends along the first side surface and the second side surface. The body of the burner panel has no internal plumbing for cooling.