Spray-Cooled Copper Burner Panel for Faster Furnace Maintenance

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Solution Overview

Problem

Conventional copper burner panels for metallurgical furnaces require complex and expensive maintenance due to their weight, size, and the difficulty in removing, repairing, and replacing them, necessitating a more efficient and cost-effective cooling solution.

Innovation Solution

A spray-cooled burner panel with an integrated non-pressurized cooling system that uses a fluid-based coolant, such as water, to regulate temperature, eliminating the need for separate high-pressure cooling piping and allowing for easier installation and removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional copper burner panels with tubular water cooling are used, then thermal performance is improved, but maintenance cost and time increase

Engineering Contradiction:

Improvethermal performanceVSAvoidmaintenance time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The burner panel is divided into modular segments that can be independently removed and replaced. The cooling system is integrated as a self-contained unit within the panel, allowing the entire cooling assembly to be replaced as one module rather than requiring complex disassembly of separate piping systems.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cooling system is merged with the burner panel structure itself, forming an integrated unit. The copper panel incorporates internal cooling channels directly into its body, eliminating the need for external high-pressure piping and creating a unified component that maintains thermal performance while simplifying maintenance.

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If conventional copper burner panels with tubular water cooling are used, then thermal performance is improved, but device complexity increases

Engineering Contradiction:

Improvethermal performanceVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The complex high-pressure piping system is extracted and replaced with a simplified integrated cooling design. The essential cooling function is retained through internal channels formed as part of the panel structure, removing the need for separate external piping infrastructure.

Inventive Principle:

Principle #2Taking out (Extraction)

3Temperature

If conventional copper burner panels are used, then heat transfer capability is improved, but weight increases

Engineering Contradiction:

Improveheat transfer capabilityVSAvoidpanel weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

Instead of using thick copper throughout the entire panel structure, the invention applies copper cooling channels only in the specific locations where heat transfer is most critical. The panel structure uses other materials or thinner sections where extreme heat resistance is less demanding, optimizing the weight-to-thermal-performance ratio.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The burner panel employs composite construction, combining copper elements (specifically for cooling channels) with other materials for the structural portions. This composite approach maintains the superior heat transfer properties of copper where needed while reducing overall weight through the use of lighter materials in non-critical areas.

Inventive Principle:

Principle #40Composite materials

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 integrated spray-cooling system reduces maintenance costs and time, improves thermal performance, and allows for quicker panel changes without extensive pipe-work, while using less material and reducing overall weight.

Implementation Method 1

As the fluid-based coolant contacts the external surface of the plate, the plate is relieved of heat transferred to the plate from the molten materials within the furnace

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

sprays a fluid-based coolant (e.g., water) against an external surface of plate that comprises the roof, sidewall or other hot surface of the furnace

Methodology Applied

Scientific EffectConvection cooling: Convection

Data Source

PatentUS12601545B2Stand alone copper burner panel for a metallurgical furnace

Publication Date: 2026.04.14 SYSTEMS SPRAY COOLED INC

AI summary

One or more embodiments of a burner panel for a metallurgical furnace is described herein. The burner panel has a body having a top surface, a bottom surface, a left surface, a right surface, and a front surface surrounding an interior burner area. A spray-cool system disposed in the interior area. A burner tube at least partially disposed in the interior burner area and extends into the front surface. The burner tube is configured to accept a burner.