Thin Stave Cooler Supporting Frame System
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Solution Overview
Problem
Conventional stave coolers for metallurgical furnaces are costly to manufacture and install due to the need for extensive machining, hot working, and potential leaks from large copper grain sizes, which compromise their durability and leak tightness, while thinner coolers lack strength and are prone to installation complexities.
Innovation Solution
A supporting frame system is integrated with thin stave coolers to enhance strength and rigidity, reducing manufacturing costs and installation time by allowing lighter, simplified cooler designs with protection sleeves providing both primary and secondary support, and isolating water piping connections through the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thick copper stave coolers are used, then strength and leak tightness are improved, but manufacturing cost and installation complexity increase
Solution Approach 1:
The cooler system is divided into two functional components: a thin copper stave cooler for heat dissipation and a separate supporting frame for structural strength. This segmentation allows each component to be optimized independently - the copper stave can be made thin and inexpensive while the supporting frame provides the necessary strength and rigidity.
Solution Approach 2:
The invention creates a composite structure combining thin copper stave coolers with supporting frames made of different materials (such as steel or iron). This composite approach allows the system to achieve both the thermal performance of copper and the structural strength of the supporting frame, while reducing overall material costs.
2Ease of manufacture
If thin stave coolers are used, then manufacturing cost is reduced, but strength and rigidity deteriorate
Solution Approach 1:
The cooler system is divided into two functional components: a thin copper stave cooler for heat dissipation and a separate supporting frame for structural strength. This segmentation allows each component to be optimized independently - the copper stave can be made thin and inexpensive while the supporting frame provides the necessary strength and rigidity.
Solution Approach 2:
The supporting frame acts as an intermediary structural element that mediates between the thin copper stave cooler and the furnace wall. It provides the necessary mechanical support and rigidity to the thin cooler, allowing it to withstand thermal and mechanical stresses without compromising its thin design.
3Reliability
If extensive machining and hot working are performed, then leak tightness is improved, but manufacturing time and cost increase
Solution Approach 1:
The cooler system is divided into two functional components: a thin copper stave cooler for heat dissipation and a separate supporting frame for structural strength. This segmentation allows each component to be optimized independently - the copper stave can be made thin and inexpensive while the supporting frame provides the necessary strength and rigidity.
Solution Approach 2:
The invention changes the manufacturing parameters by eliminating the need for extensive hot working and machining of the copper stave coolers. The thin copper staves can be manufactured through simpler processes such as rolling or forming, reducing manufacturing time and cost while maintaining leak tightness through proper joint design and sealing methods.
4Ease of manufacture
If copper grain size is increased, then manufacturing cost is reduced, but leak tightness deteriorates
Solution Approach 1:
The cooler system is divided into two functional components: a thin copper stave cooler for heat dissipation and a separate supporting frame for structural strength. This segmentation allows each component to be optimized independently - the copper stave can be made thin and inexpensive while the supporting frame provides the necessary strength and rigidity.
Solution Approach 2:
The invention changes the manufacturing parameters by eliminating the need for extensive hot working and machining of the copper stave coolers. The thin copper staves can be manufactured through simpler processes such as rolling or forming, reducing manufacturing time and cost while maintaining leak tightness through proper joint design and sealing methods.
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 significantly reduces manufacturing and installation costs while maintaining performance by providing a robust and leak-resistant stave cooler system that can be easily adapted to various furnace configurations, extending campaign life and simplifying the installation process.
Implementation Method 1
A supporting frame system is integrated with thin stave coolers to enhance strength and rigidity
Implementation Method 2
protection sleeves providing both primary and secondary support, and isolating water piping connections through the frame
Implementation Method 3
Water is circulated in the stave cooler through feed and discharge piping connections
Data Source
AI summary
A supporting frame and thin stave cooler for a metallurgical furnace comprises a metal structure fastened to the cold face of the thin stave cooler that adds strength and rigidity. The thin stave cooler itself is lightened, thinned, and simplified to take optimal advantage of the supporting frame and its provisions for mounting and attaching the thin stave cooler assembly to the inside walls of a furnace containment shell. Water is circulated in the thin stave cooler through feed and discharge piping connections that pass through the supporting frame and are sleeved by protection sleeves. The protection sleeves can serve as a primary or secondary support system when they are welded between the furnace containment shell and the supporting frame when first installed.