Splash Protection Device Cooling with Boiling Water
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Solution Overview
Problem
The existing splash protection devices in copper melting furnaces suffer from erosion corrosion due to sulfur in the copper melt, leading to a short useful lifetime and potential cold water penetration if cracks occur, causing explosive copper splashing and boiler damage.
Innovation Solution
Using boiling water under pressure above 5 bar to cool the splash protection device, which increases its temperature above 200°C, preventing erosion corrosion and ensuring that any leaks result in immediate evaporation of water, thus preventing cold water from entering the melt, and utilizing steel pipes with a monolithic lining for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cold cooling water is used to cool the splash protection device, then copper melting is effectively prevented, but erosion corrosion occurs due to sulfur in the copper melt, reducing the device lifetime
Solution Approach 1:
The invention changes the temperature parameter of the cooling water from cold (below 100°C) to boiling (above 100°C). This parameter change fundamentally alters the interaction between the cooling water and the copper melt, preventing erosion corrosion while maintaining effective cooling. The boiling water temperature creates a protective steam barrier that eliminates the corrosive effect of sulfur in the melt.
Solution Approach 2:
The invention converts the potential harm of water contact with hot copper (which could cause explosive vaporization and damage) into a beneficial protective mechanism. By using boiling water, any water that contacts the copper melt immediately vaporizes harmlessly, and the steam formed actually protects the splash protection device from erosion corrosion by creating a protective atmosphere.
2Temperature
If cold cooling water is used in the splash protection device, then copper melting is prevented, but cracks allow cold water to penetrate into the copper melt causing explosive splashing
Solution Approach 1:
The invention applies beforehand cushioning by pre-heating the cooling water to boiling point before it contacts the splash protection device. This ensures that if cracks develop and water penetrates into the copper melt, the water is already at boiling temperature and will not cause explosive vaporization. The harmful effect is cushioned in advance by the temperature preparation of the cooling medium.
Solution Approach 2:
The invention converts the potential catastrophic harm of water penetrating into the copper melt into a harmless or even beneficial effect. By using boiling water, any leakage results in immediate vaporization that does not cause explosive splashing, and the steam may actually help protect the surrounding equipment from copper droplets.
3Temperature
If the splash protection device is cooled with water, then copper melting is prevented, but the device requires frequent replacement due to erosion corrosion
Solution Approach 1:
The invention changes the temperature parameter of the cooling water from cold to boiling, which fundamentally alters the chemical and physical interaction with the copper melt. This parameter change eliminates erosion corrosion caused by sulfur, thereby dramatically extending the service life of the splash protection device while maintaining its temperature control function.
Solution Approach 2:
The invention ensures continuous protection by making the cooling water flow continuously through the splash protection device at boiling temperature. This continuous flow of hot water maintains the protective steam barrier around the device, preventing erosion corrosion throughout its operational life and ensuring uninterrupted protection against copper splashing.
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 method significantly extends the lifespan of the splash protection device by preventing erosion corrosion and ensuring that any leaks result in steam formation, avoiding the introduction of cold water into the copper melt, thereby reducing the risk of explosive copper splashing and protecting the waste heat boiler.
Implementation Method 1
The water is passed along the chimney wall in long, vertical riser lines. Because of the great height of the chimney, a vigorous water circulation occurs in the riser lines, in this connection, allowing effective cooling of the chimney wall.
Implementation Method 2
using boiling water for cooling the splash protection device. The water is under a pressure of more than 5 bar and reaches boiling temperature as it flows through the splash protection device.
Implementation Method 3
if another kind of leak occurs, no cold water gets into the copper melt, because the boiling water evaporates immediately upon entering the melting furnace atmosphere.
Implementation Method 4
The water is under a pressure of more than 5 bar and reaches boiling temperature as it flows through the splash protection device.
Data Source
AI summary
A method for obtaining pure copper is provided wherein oxygen is blown onto a copper melt, in a melting furnace lined with refractory material, having a waste heat boiler set onto it, in order to oxidize contaminants contained in the melt and thereby remove them from the melt, and wherein a splash protection device through which water flows is provided above the copper melt, on the inside wall of the melting furnace, which prevents copper that splashes out of the copper melt from penetrating into the waste heat boiler. Boiling water is used for cooling the splash protection device, which water is under a pressure of more than 5 bar and is evaporated, at least in part, as it flows through the splash protection device.