Refractory Delta Cooling System for Electric Arc Furnace
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Solution Overview
Problem
Refractory deltas in electric arc furnace roofs are susceptible to damage from heat generated by electrode arcs, leading to premature wear and increased downtime for repairs, as they are exposed to intense heat during the melting process, especially when scrap steel is charged near the roof.
Innovation Solution
Incorporating cooling apertures and channels within refractory deltas to direct cooling liquids, such as water, from the cold-face to the hot-face, where the water evaporates and continues to draw heat away, potentially using copper tubes to enhance heat transfer, thereby reducing the thermal stress on the refractory material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If refractory deltas are used to protect the roof from heat, then thermal insulation is improved, but the refractory material wears away prematurely due to intense heat exposure
Solution Approach 1:
The patent introduces a cooling liquid (water) as an intermediary substance that flows through channels in the refractory delta. This cooling liquid acts as a mediator between the hot refractory material and the external cooling system, absorbing heat through convection and evaporation to protect the refractory delta from thermal damage and extend its service life
Solution Approach 2:
The patent employs a hydraulic cooling system where cooling liquid is pumped through channels formed in the refractory delta. The pressurized liquid flow enables effective heat removal from the refractory material, allowing the system to withstand high temperatures while extending the operational duration of the refractory components
2Temperature
If cooling liquid is directed through the refractory delta, then heat transfer is improved and thermal stress is reduced, but the system complexity increases
Solution Approach 1:
The patent combines the cooling channels directly into the refractory delta structure itself, merging the cooling system with the thermal protection component. This integration eliminates the need for separate cooling apparatus and reduces overall system complexity while maintaining effective heat transfer
Solution Approach 2:
The refractory delta incorporates internal channels that allow cooling liquid to permeate through the material structure. This porous-like configuration enables distributed cooling throughout the refractory delta, improving heat transfer efficiency without requiring complex external cooling mechanisms
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 solution extends the life of refractory deltas by 1.5 to 3 times, on average by a factor of 2, allowing for longer operation between replacements and reducing maintenance downtime, as the cooling system effectively manages heat transfer and reduces wear from arc-related damage.
Implementation Method 1
The water draws heat from the surrounding refractory material in the refractory deltas as the water passes through the one or more apertures
Implementation Method 2
The water evaporates as it passes through the one or more apertures and when it enters the EAFs
Data Source
AI summary
Embodiments of the present invention comprise a refractory delta made from a refractory material having a cold-face side and a hot-face side. One or more electrode apertures are located in the refractory delta for receiving one or more electrodes. One or more cooling apertures extend from the cold-face side of the refractory material to adjacent the hot-face side of the refractory material. The one or more cooling apertures may further comprise a copper tube. A cooling system delivers a cooling liquid to the one or more cooling apertures, and the cooling liquid draws heat from the adjacent refractory material, including the hot-face side, and evaporates to allow replacement cooling liquid to further draw heat from the adjacent refractory material.