Standalone Copper Burner Panel With Integrated Spray Cooling
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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 cooling system that uses a non-pressurized spray-cooling method to cool the burner panel, eliminating the need for separate high-pressure cooling piping and incorporating a drain system directly into the panel design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional copper burner panels with separate high-pressure cooling piping are used, then the burner panel can withstand intense heat loads, but the maintenance becomes complex and expensive due to weight, size, and difficulty in removing, repairing, and replacing
Solution Approach 1:
The cooling system is integrated directly into the burner panel body, merging the cooling function with the structural component. This eliminates separate cooling pipes and reduces the number of parts that need maintenance, directly addressing the maintenance difficulty while preserving heat resistance through the integrated cooling channels
Solution Approach 2:
The burner panel is designed as a modular assembly with the cooling system integrated into the copper body. This segmentation allows the entire cooling system to move with the burner panel, making removal and installation simpler while maintaining the heat dissipation function through integrated cooling passages
2Temperature
If conventional burner panels with separate cooling systems are used, then adequate cooling is provided, but the installation and replacement process becomes time-consuming and labor-intensive
Solution Approach 1:
The cooling system is combined with the burner panel into a single integrated unit. This merger means that when the burner panel is installed or replaced, the cooling system moves with it, eliminating the need for separate installation and disconnection of cooling pipes, thus reducing assembly and disassembly time while maintaining cooling effectiveness
Solution Approach 2:
The integrated design allows the burner panel to carry its own cooling system, making the panel self-sufficient. This self-service approach eliminates dependency on external cooling infrastructure during installation and replacement, reducing labor requirements and time loss while ensuring continuous cooling capability
3Strength
If conventional burner panels are mechanically fixed in place to seal openings, then the panel provides structural support and sealing, but the weight and size make removal and replacement difficult and expensive
Solution Approach 1:
The sealing and structural functions are merged into the integrated burner panel assembly with built-in cooling. This unified design maintains the sealing capability through the integrated structure while reducing the overall weight compared to conventional separate cooling systems, making installation and removal easier and less expensive
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
Reduces maintenance costs and simplifies the installation and replacement process by integrating the cooling system within the panel, allowing for quicker and more efficient thermal management without extensive pipe-work.
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, thus regulating the temperature of the plate
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
Data Source
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.