Multilayer Cooling Panel for Electric Arc Furnace
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric arc furnace cooling systems face issues with thermal expansion mismatch between refractory materials and metallic cooling tubes, leading to spalling, and are not stable against basic process slags, resulting in energy inefficiencies and reduced lifespan.
Innovation Solution
A multilayer cooling panel design featuring pre-shaped refractory ceramic plates as a thermal, chemical, and metallurgical barrier between the furnace chamber and cooling pipes, with a gap between pipes and plates to prevent direct contact and allow for efficient insulation, using refractory materials like MgO-based ceramics with a profiled surface for enhanced slag adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lining material such as refractory monolithic or metallurgical slag is applied directly onto the cooling tubes' surfaces, then the cooling tubes are protected, but thermal expansion mismatch causes spalling and reduces system lifespan
Solution Approach 1:
The patent introduces refractory ceramic plates as an intermediary barrier between the furnace chamber and cooling pipes. These plates are fixed to the cooling pipes with a detachable/suspended fixture, creating a thermal, chemical, and metallurgical barrier that prevents direct contact between slag and cooling pipes while accommodating thermal expansion differences through the flexible mounting system.
Solution Approach 2:
The cooling wall is divided into multiple layers: an outer layer with cooling tubes and an inner layer of refractory ceramic plates. This segmentation allows each layer to perform its specific function independently - the cooling tubes provide cooling while the refractory plates provide protection against thermal and chemical attacks.
2Object-affected harmful factors
If basic refractory material is used to protect cooling tubes, then protection against slag is improved, but thermal expansion coefficient mismatch with metallic cooling pipes leads to spalling
Solution Approach 1:
The refractory ceramic plates serve as a mediator that provides chemical resistance to basic slags while being mechanically decoupled from the metallic cooling pipes through a detachable fixture. This allows the plates to maintain their protective function without transferring thermal expansion stresses to the metal tubes.
3Stability of the object's composition
If alumina (Al2O3) is used as refractory material, then thermal expansion compatibility is improved, but stability against basic process slags is lost
Solution Approach 1:
The patent changes the material parameter of the refractory lining from alumina to magnesia-based ceramics, which have appropriate chemical stability against basic slags. The thermal expansion compatibility issue is simultaneously resolved by changing the mounting method from rigid adhesion to detachable/suspended fixation, allowing independent thermal movement.
4Device complexity
If cooling tubes are directly exposed to furnace chamber, then system complexity is reduced, but energy losses increase due to insufficient insulation
Solution Approach 1:
The patent adds a spatial dimension by introducing a gap between the cooling tubes and the refractory ceramic plates. This gap acts as an insulation space that reduces heat flow to the cooling fluid while maintaining a relatively simple tube structure, thereby reducing energy losses without significantly increasing complexity.
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 provides improved thermal insulation, reduces energy losses, and extends the lifespan of the cooling system by preventing spalling and metallurgical attacks, allowing for easy replacement of refractory plates without dismantling the entire furnace shell.
Implementation Method 1
They provide an efficient screening wall against thermal radiation
Implementation Method 2
They provide an efficient screening wall against thermal radiation, even high energy radiation deriving from unshielded electric arcs
Implementation Method 3
refractory materials like MgO-based ceramics with a profiled surface for enhanced slag adherence
Data Source
Figure 1~3
Figure 4
Figure 5
AI summary
The invention relates to a multilayer cooling panel for an industrial furnace such as an electric arc furnace.