Gap-Filler Insert for Metallurgical Furnace Cooling Plates
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Solution Overview
Problem
Cooling plates in metallurgical furnaces experience uneven erosion due to the absence of protective layers, leading to deterioration of backfilling concrete and subsequent uneven wear, which shortens their lifespan.
Innovation Solution
A gap-filler insert made of high wear-resistant metal, such as Creusabro® or Hardox®, is placed between cooling plates, featuring anchoring means like lateral legs or connecting arms to securely fit between edge faces, ensuring the front plate is flush with the cooling plates' faces, thereby sealing gaps and preventing concrete erosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cooling plates are mounted directly against the furnace wall with backfilling concrete in the gaps, then the structure is simple and easy to install, but the backfilling concrete deteriorates due to harsh conditions causing uneven erosion of cooling plates
Solution Approach 1:
A gap-filler insert is introduced as an intermediary component between neighboring cooling plates. This insert comprises a front plate made of wear-resistant material that faces the furnace interior and a back plate that abuts the rear faces of cooling plates, with connecting elements joining them. The front plate protects the backfilling concrete in the gaps from deterioration caused by harsh furnace conditions, while the back plate provides anchoring to the cooling plates. This intermediary structure prevents direct exposure of the concrete to erosive forces.
2Ease of operation
If cooling plates are operated without protective layers (refractory brick lining, guniting, or accretion layer), then operation is simpler and more direct, but the cooling plates experience uneven erosion and shortened lifespan
Solution Approach 1:
The gap-filler insert applies local quality by providing wear-resistant protection specifically at the gap regions between cooling plates, rather than requiring a complete protective layer over the entire cooling plate surface. The front plate is made of material with high wear resistance to withstand direct exposure to harsh furnace conditions, while the main body of the cooling plate can operate without a full protective coating. This localized protection allows simpler operation while preventing erosion at critical gap areas.
3Ease of manufacture
If gaps between cooling plates are filled with backfilling concrete only, then installation is straightforward, but the concrete erodes unevenly contributing to cooling plate deterioration
Solution Approach 1:
The gap-filler insert employs composite material construction, combining a front plate made of wear-resistant material (such as high-chromium cast iron or similar erosion-resistant alloy) with a back plate and connecting elements that can be made of different materials suitable for structural attachment. This composite structure integrates the erosion-resistant properties of the front plate with the structural properties of the backing components, creating a unified element that both fills the gap and protects against concrete erosion while maintaining ease of installation as a pre-assembled unit.
Data Source
AI summary
The present invention proposes a gap-filler insert (20) for use with cooling plates (12, 12′) for a metallurgical furnace, the cooling plates (12, 12′) having a front face (14, 14′) directed towards the interior of the furnace, an opposite rear face (16, 16′) directed towards a furnace wall (10) of the furnace and four edge faces (18, 18′). In accordance with an aspect of the present invention, the gap-filler insert (20) comprises a metal front plate (24) with a front side (24) facing the interior of the furnace and anchoring means (28, 28′, 30, 30′, 32, 34) for mounting the front plate (24) between two neighboring cooling plates (12, 12′) in such a way that the front plate (24) extends between the edge faces (18, 18′) of both cooling plates (12, 12′), and that the front side (26) of the front plate (24) is flush with the front faces (14, 14′) of both cooling plates (12, 12′).