1. Furnace Sidewall Cooling

Furnace Sidewall Cooling

Tenova's copper products use the freeze lining principle to reduce component wear. Lower wear means longer launder life, cutting long-term maintenance costs and downtime production losses.

Cooling of the refractory lining is a fundamental aspect of furnace operations. Lining life is often determined by abnormal operating events and extreme operating conditions. To improve lining life and guarantee extended performance, particular care must be given to design, installation, drying and cleaning of the equipment together with a proper cooling system.

Water-cooled copper components use the freeze lining principle to reduce component wear. Lower wear means longer launder life, cutting long-term maintenance costs and downtime production losses. The design of Tenova Pyromet water-cooled copper components and copper launders eliminates inherent risk to personnel and equipment safety.

Using computer-aided design (CAD) and finite element analysis (FEA) techniques, Tenova Pyromet optimizes the design of copper cooling systems for:

  • Heat removal capacity.
  • Copper and lining maximum operating temperatures.
  • Cooling-water contact area and flow characteristics.
  • Temperature gradients on the lining hot face.
  • Efficient use of copper.
  • Use with heat transfer fluids other than water.

All Tenova Pyromet copper cooling elements are manufactured and tested to stringent standards to ensure products of the highest quality, capable of exceeding design performance.

  • Efficiency

    Efficiency

    • Higher power density levels can be maintained, for higher furnace throughput
    • Lower Heat Losses, the insulating freeze lining reduces energy losses from the furnace.
  • Safety

    Safety

    • External water passages on SAFECOOL cooler designs keep water outside the furnace
    • Cast-in monel tubes in MAXICOOL coolers eliminate the risk if water leaks caused by casting defects
    • Long-term cracks in copper due to thermal fatigue cannot extend into monel passages
    • Fusion of monel tubes with cast copper ensures excellent heat transfer

Downloads

References

  • Tenova Pyromet's MAXICOOL sidewall copper cooling system

    Customer
    Project name
    Anglo Platinum
    South Africa
    2003

    "The design and supply of the key furnace equipment, including Tenova Pyromet’s MAXICOOL® sidewall copper cooling system, Tenova Pyromet’s patented electrode column and copper launder system, as well as the furnace shell and feed system."

    The MAXICOOL® system is an intensive sidewall cooling system for liquid bath operations designed for heat loads of up to 500 kW/m2. For increased safety, the cooler panels were designed to operate with synthetic oil rather than water.

  • Befesa Valera S.A.S.

    Customer
    Project name
    Befesa Valera S.A.S
    Gravelines, France
    2007

    Designed by Tenova Pyromet, the furnace shell is fitted with Patented Safecool® copper coolers to provide a freeze lining. The coolers cool the slag, which then freezes onto the inside of the furnace, thereby creating protection for the refractory lining.

  • Elkem Solar

    Customer
    Project name
    Elkem Solar
    Norway
    2009

    The design of this furnace required a unique approach since there are no reference plants of this type. Tenova Pyromet worked closely with the client and successfully designed a furnace from first principles. This resulted in an innovative and unique solution. World class technology was installed in this furnace including: a new generation furnace controller; lining management system; live video monitoring inside the closed furnace and the patented MAXICOOL ® system.

    The MAXICOOL® system is an intensive sidewall cooling system for liquid bath operations designed for heat loads of up to 500 kW/m2. For increased safety, the cooler panels were designed to operate with synthetic oil rather than water.

    Project Figures

    2.5 MVA
  • ContactContact PersonPositionLegal EntityDepartmentPhoneFaxE-mailAddress
    Tenova South Africa (PTY) Ltd.
    General
    +27 11480 2000
    +27 8674 30389
    pyromet@tenova.com

    Midrand Business Park, Building no 4, 563 Old Pretoria, Main Road Halfway House, Midrand, Johannesburg

    1685 Johannesburg

    South Africa

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News

Water cooled Copper Elements

Tenova copper products, including copper coolers, water cooled copper launders, water cooled copper tap holes and other specialty products, are designed using advanced techniques such as FEA and CFD. Tenova copper products are manufactured with high purity copper to exacting quality standards.