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Title: Copper staves in the blast furnace

Abstract

Operational data for stave cooling systems for two German blast furnaces show good correlation with predicted thermal results. Copper staves have been installed in blast furnaces in the zones exposed to the highest thermal loads. The good operational results achieved confirm the choice of copper staves in the areas of maximum heat load. Both temperature measurements and predictions establish that the MAN GHH copper staves do not experience large temperature fluctuations and that the hot face temperatures will be below 250 F. This suggests that the copper staves maintain a more stable accretion layer than the cast iron staves. Contrary to initial expectations, heat flux to the copper staves is 50% lower than that to cast iron staves. The more stable accretion layer acts as an excellent insulator for the stave and greatly reduces the number of times the hot face of the stave is exposed to the blast furnace process and should result in a more stable furnace operation. In the future, it may be unnecessary to use high quality, expensive refractories in front of copper staves because of the highly stable accretion layer that appears to rapidly form due to the lower operating temperature of the staves. Theremore » is a balance of application regions for cast iron and copper staves that minimizes the capital cost of a blast furnace reline and provides an integrated cooling system with multiple campaign life potential. Cast iron staves are proven cooling elements that are capable of multiple campaign life in areas of the blast furnace which do not experience extreme heat loads. Copper staves are proving to be an effective and reliable blast furnace cooling element that are subject to virtually no wear and are projected to have a longer campaign service life in the areas of highest thermal load in the blast furnace.« less

Authors:
 [1];  [2];  [3];  [4]
  1. ATSI, Inc., Amherst, NY (United States)
  2. Thyssen Stahl AG, Duisburg (Germany)
  3. Preussag Stahl AG, Saltzgitter (Germany)
  4. MAN GHH AG, Oberhausen (Germany)
Publication Date:
OSTI Identifier:
367895
Resource Type:
Journal Article
Journal Name:
Iron and Steel Engineer
Additional Journal Information:
Journal Volume: 73; Journal Issue: 8; Other Information: PBD: Aug 1996
Country of Publication:
United States
Language:
English
Subject:
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; 01 COAL, LIGNITE, AND PEAT; BLAST FURNACES; COOLING SYSTEMS; MATERIALS; COPPER; MATERIAL SUBSTITUTION; CAST IRON; THERMAL INSULATION; SERVICE LIFE; THERMAL STRESSES; WEAR RESISTANCE

Citation Formats

Helenbrook, R G, Kowalski, W, Grosspietsch, K H, and Hille, H. Copper staves in the blast furnace. United States: N. p., 1996. Web.
Helenbrook, R G, Kowalski, W, Grosspietsch, K H, & Hille, H. Copper staves in the blast furnace. United States.
Helenbrook, R G, Kowalski, W, Grosspietsch, K H, and Hille, H. 1996. "Copper staves in the blast furnace". United States.
@article{osti_367895,
title = {Copper staves in the blast furnace},
author = {Helenbrook, R G and Kowalski, W and Grosspietsch, K H and Hille, H},
abstractNote = {Operational data for stave cooling systems for two German blast furnaces show good correlation with predicted thermal results. Copper staves have been installed in blast furnaces in the zones exposed to the highest thermal loads. The good operational results achieved confirm the choice of copper staves in the areas of maximum heat load. Both temperature measurements and predictions establish that the MAN GHH copper staves do not experience large temperature fluctuations and that the hot face temperatures will be below 250 F. This suggests that the copper staves maintain a more stable accretion layer than the cast iron staves. Contrary to initial expectations, heat flux to the copper staves is 50% lower than that to cast iron staves. The more stable accretion layer acts as an excellent insulator for the stave and greatly reduces the number of times the hot face of the stave is exposed to the blast furnace process and should result in a more stable furnace operation. In the future, it may be unnecessary to use high quality, expensive refractories in front of copper staves because of the highly stable accretion layer that appears to rapidly form due to the lower operating temperature of the staves. There is a balance of application regions for cast iron and copper staves that minimizes the capital cost of a blast furnace reline and provides an integrated cooling system with multiple campaign life potential. Cast iron staves are proven cooling elements that are capable of multiple campaign life in areas of the blast furnace which do not experience extreme heat loads. Copper staves are proving to be an effective and reliable blast furnace cooling element that are subject to virtually no wear and are projected to have a longer campaign service life in the areas of highest thermal load in the blast furnace.},
doi = {},
url = {https://www.osti.gov/biblio/367895}, journal = {Iron and Steel Engineer},
number = 8,
volume = 73,
place = {United States},
year = {Thu Aug 01 00:00:00 EDT 1996},
month = {Thu Aug 01 00:00:00 EDT 1996}
}