Stave Cooler Anchor Ring Embedding for Gas-Tight Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solutions for attaching stave coolers in blast furnaces fail to provide a secure, long-term seal against lethal process gases and support the heavy weight of the coolers, leading to potential detachment and gas leakage over time.
Innovation Solution
A steel footer/anchor ring is embedded in the stave copper casting using exotic dissimilar metal welding or entrained liquid copper, with a carbon steel pipe collection box welded on for gas-tight and weight-bearing support, ensuring the stave cooler remains securely attached and gas-tight throughout its campaign life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a steel footer/anchor ring is embedded in stave copper casting using exotic dissimilar metal welding, then the gas-tight seal and mechanical strength are improved, but the manufacturing complexity and difficulty increase
Solution Approach 1:
The patent introduces an intermediary material (exotic dissimilar metal welding material or entrained liquid copper) that acts as a mediator between the steel footer/anchor ring and the copper casting. This intermediary enables reliable bonding between dissimilar metals (steel and copper) that would otherwise be difficult to weld directly, achieving both gas-tight sealing and mechanical strength while managing the complexity through a specialized intermediate layer.
Solution Approach 2:
The patent employs composite material construction by combining steel footer/anchor ring with copper casting through exotic dissimilar metal welding or copper entrainment. This creates a hybrid structure that leverages the strengths of both materials (steel's strength and copper's thermal conductivity and castability) to achieve reliable gas-tight sealing while supporting heavy stave cooler weights.
2Strength
If a pipe collection box is welded on to support the stave cooler weight, then the weight-bearing capacity is improved, but the manufacturing complexity increases
Solution Approach 1:
The steel footer/anchor ring is embedded in the copper casting during the initial casting process, performing preliminary anchoring action. This pre-established foundation simplifies subsequent assembly by providing ready-made mounting points for the pipe collection box, reducing the need for complex field modifications or additional structural components to support the stave cooler weight.
Solution Approach 2:
The patent merges multiple functions into integrated components: the steel footer serves both as an anchor for the copper casting and as a base for mounting the pipe collection box. The pipe collection box itself combines weight-bearing support with gas-tight containment of process gases, eliminating the need for separate structural and sealing components.
3Reliability
If exotic dissimilar metal welding or entrained liquid copper is used to embed the anchor ring, then the mechanical strength and gas-tightness are improved, but the ease of manufacture decreases
Solution Approach 1:
The patent utilizes phase transitions of copper (liquid to solid) during the casting process to embed the steel anchor ring. Liquid copper is poured around the pre-positioned steel footer, and as it solidifies, it mechanically locks and bonds to the steel. This phase change approach simplifies manufacturing compared to post-casting welding operations, as the embedding occurs automatically during the normal casting process.
Solution Approach 2:
The entrained liquid copper method allows the casting process itself to perform the embedding and bonding function. The liquid copper flows around and encapsulates the steel footer during pouring, and upon solidification, creates the mechanical bond without requiring separate welding or fastening operations. The process serves itself by using the casting material to create the attachment.
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 effectively maintains a gas-tight seal and supports the weight of the stave cooler, preventing detachment and leakage, ensuring the stability and longevity of the blast furnace operation.
Implementation Method 1
by entrained liquid copper that passed through and froze inside openings preformed in the steel footer rings
Implementation Method 2
using exotic dissimilar metal welding
Data Source
AI summary
A water pipe collection box and stave support for a cast copper stave cooler body panel that has disposed within it a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends clustered together in a single group that exits a backside of the copper stave cooler body panel. A cast copper stave cooler body panel that has disposed within a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends clustered together in a single group that exits a backside of the copper stave cooler body panel. A blast furnace having stave cooler body panels variously profiled to fit inside, and where each has disposed within it a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends are clustered together in a single group that exits a backside of each copper stave cooler body panel.