Gas Injection System Cooling Channels for Furnace Wear Reduction

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Solution Overview

Problem

Gas injection systems in steel production, particularly in electric arc furnaces, face issues with burner wear due to thermal and mechanical stresses, leading to inefficient heat transfer and reduced lifespan, with existing cooling systems causing foaming and heat exchange inefficiencies.

Innovation Solution

A monobloc tubular wall with axial channels and rounded connecting channels that form a compact, continuous heat conduction path, minimizing thermal resistance and preventing foaming, combined with a closing crown for enhanced structural integrity and heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If cooling channels are arranged coaxially in the burner wall, then cooling fluid can be circulated, but the cooling fluid foams at the distal extremity reducing cooling efficiency

Engineering Contradiction:

Improvecooling efficiencyVSAvoidcooling system performance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The connecting channels between axial cooling channels are designed with rounded shapes instead of sharp angles, creating smooth transitions that prevent turbulence and foaming of the cooling fluid. This curvature principle eliminates the harmful foaming effect while maintaining effective heat extraction from the burner wall.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Temperature

If cooling channels are arranged coaxially, then cooling is provided, but hot return fluid exchanges heat with incoming cold fluid before reaching thermally stressed areas

Engineering Contradiction:

Improvecooling fluid temperature distributionVSAvoidheat exchange efficiency

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The cooling system is segmented into separate incoming and return fluid paths that do not mix. The rounded connecting channels create distinct flow zones, preventing premature heat exchange between hot return fluid and cold incoming fluid, thereby maintaining optimal temperature gradients for efficient cooling.

Inventive Principle:

Principle #1Segmentation

3Productivity

If burners are subjected to thermal and mechanical stresses during casting cycles, then they perform their function, but they wear out by erosion and cracking reducing lifespan

Engineering Contradiction:

Improvecasting cycle performanceVSAvoidburner lifespan

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The cooling system is designed to preemptively protect the burner wall from thermal damage by establishing continuous cooling fluid flow through rounded channels before thermal stresses can cause erosion or cracking. This preliminary cooling action prevents the formation of thermal cracks and reduces erosion during casting cycles.

Inventive Principle:

Principle #10Preliminary action

4Ease of operation

If axial cooling channels are connected with abrupt direction changes, then cooling fluid circulates, but foaming occurs and heat transfer efficiency decreases

Engineering Contradiction:

Improvecooling fluid circulationVSAvoidheat transfer efficiency

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

All direction changes in the cooling channels are designed with rounded shapes, eliminating abrupt angles and sharp transitions. This ensures smooth cooling fluid circulation without foaming, maintaining high heat transfer efficiency while enabling effective cooling fluid movement through the burner wall.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 solution increases the lifespan of gas injection systems by ensuring high heat transfer efficiency and uniform temperature distribution, reducing cracking and foaming, while maintaining high flow velocities and heat extraction capabilities.

Implementation Method 1

a cooling system located in said tubular wall and comprising axial channels which, between a proximal terminal and a distal terminal, extend axially towards said distal extremity of the tubular wall and in which a cooling fluid is circulated

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

in which a cooling fluid is circulated

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

these connecting channels having a rounded shape in the direction of the distal extremity of the tubular wall

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 4

minimizing thermal resistance and preventing foaming

Methodology Applied

Scientific EffectPreventing foaming:

Data Source

PatentUS11662145B2Gas injection system, furnace provided with such a system and use thereof

Publication Date: 2023.05.30 SOUDOBEAM SA

AI summary

A gas injection system includes a tubular wall 3 capable of being thermally stressed and having a proximal extremity and a distal extremity 11, at the distal extremity, at least one extremity opening through which at least one gas is projected. A cooling is system located in the tubular wall including axial channels 12 which extend axially towards the distal extremity and in which a cooling fluid is circulated. Connecting channels 13 circumferentially join the axial channels to each other at the distal extremity of the tubular wall. The connecting channels, which circumferentially join the axial channels at the distal extremity of the tubular wall, have a rounded shape in the direction of the distal extremity.