Abstract: A shaft furnace, in particular a blast furnace, includes a metal jacket defining the furnace outer wall and a protective layer protecting the inner surface of the outer wall. At least one condition monitoring probe is arranged inside within the protective layer to monitor the latter. The condition monitoring probe is connected to a wireless module arranged outside the outer wall to transmit condition monitoring data. The wireless module is located inside a casing mounted to the outer surface of the metal jacket. The condition monitoring probe includes one or more conductive loops positioned at predetermined depths below the front face of the cooling plate body, or of the refractory lining, so that wear of the body, resp. refractory, can be detected by a change of an electrical characteristic of the loop(s) due to abrasion.

Abstract: A method and apparatus for melting aluminum uses a dense metal salt of Rubidium, Cesium, or Strontium. The salt is melted by a stinger and then superheated by AC applied to electrodes immersed in the salt. Aluminum in contact with the salt melts and floats on the salt. In continuous scrap melting, inflows and outflows of aluminum are comparable and may be shielded by inert gas. The superheated salt may be purified and may be heated in a separate reservoir and pumped to and from another reservoir containing salt and/or metal. The salt may be used to supplement the heating of an existing furnace.

Abstract: The present invention relates to a slag discharge door device for an electric furnace, wherein slag is prevented from flowing out via a slag discharge port by making a discharge control door body move up and down to and from the upper surface of a supporting body where slag is discharged by flowing to the upper surface, and the discharge of slag is controlled, such that during steel-making work in the electric furnace, the outflow of slag is prevented and heat losses are reduced, the efficiency of arc heat due to the formation of foamed slag is increased, and valuable metals are recovered from the molten slag thereby increasing the percentage of molten steel recovered.

Abstract: An apparatus and method for use in metal melting, refining and/or other processing, such as, for example, steel making in an electric arc furnace (EAF), and more particularly, to improved burner/injector panels and related methods for the introduction of various energy sources, such as, for example, chemical energy, oxygen and particulates into an EAF.

Abstract: A pipe and method of use for deterring or encouraging the retention of slag or other material in the operating area of a metal processing system as desired. The deterring pipe(s) and the encouraging pipe(s) may be combined with other deterring pipe(s) and/or other encouraging pipe(s) in any combination as desired.

Abstract: A method and apparatus for accessing a furnace melt are provided. Preferably, the method and apparatus provide for the safe and efficient access to the molten metal melt in a furnace. According to one aspect of the invention used in a steel making process in an electric arc furnace, a furnace aperture plug is reciprocated through a furnace aperture, the furnace aperture plug is retracted from the furnace aperture, access is provided to the molten metal melt in the furnace, and the furnace aperture plug is reinserted into the furnace aperture when the access is concluded.

Abstract: The present invention generally relates to apparatuses and methods for use in metal melting, refining and/or other processing, such as, for example, steel making in an electric arc furnace (EAF), and more particularly, to improved burner panels and related methods for the introduction of various energy sources, such as, for example, chemical energy and particulates.

Abstract: The present invention generally relates to apparatuses and methods for use in metal melting, refining and/or other processing, such as, for example, steel making in an electric arc furnace (EAF), and more particularly, to improved cooling systems and related methods for use in an extended burner panel.

Abstract: A method and apparatus for accessing a furnace melt are provided. Preferably, the method and apparatus provide for the safe and efficient access to the molten metal melt in a furnace. According to one aspect of the invention used in a steel making process in an electric arc furnace, a furnace aperture plug is reciprocated through a furnace aperture, the furnace aperture plug is retracted from the furnace aperture, access is provided to the molten metal melt in the furnace, and the furnace aperture plug is reinserted into the furnace aperture when the access is concluded.

Abstract: A method and apparatus for testing characteristics of a furnace melt are provided. Preferably, the method and apparatus provide for the safe and efficient testing of metal temperature and composition of molten metal during the melt cycle of the metal. According to one aspect of the invention used in a steel making process in an electric arc furnace, a furnace probe is reciprocated through a furnace probe plug aperture, the furnace probe is retracted from the furnace probe plug aperture, a furnace probe is inserted through the furnace probe plug aperture, the furnace probe is retracted from the aperture, and the furnace probe aperture plug is inserted into the furnace probe plug aperture.

Abstract: An arrangement for protecting heat-absorptive elements in a high-temperature furnace includes a refractory member comprised of an interconnected metal structure embedded within the member and a tubular insert element capable of attaching the refractory member to the heat-absorptive element. The tubular insert has a hollow tubular body that is capable of sliding within a passageway through the embedded metal structure. The tubular insert has a rib or lip with an outer diameter larger than the passageway through the metal structure that engages the structure. When the other end of the tubular insert is connected to the heat-absorptive element, the rib holds the refractory member in place without a need to weld the tubular insert directly to the metal structure.

Abstract: A method and apparatus for increasing spatial energy coverage in a furnace is provided. The apparatus of the present invention includes a panel positioned at least partially into a sidewall of a furnace. The panel includes a plurality of openings for injecting a material through each of the openings at least partially during the same time period. The method of the present invention includes positioning the panel at least partially within the sidewall of a furnace. The method also includes injecting at least partially during the same time period, a primary combustion material, a secondary combustion material, and a particulate material, into the furnace.

Abstract: A method and apparatus for increasing spatial energy coverage in a furnace is provided. The apparatus of the present invention includes a panel positioned at least partially into a sidewall of a furnace. The panel includes a plurality of openings for injecting a material through each of the openings at least partially during the same time period. The method of the present invention includes positioning the panel at least partially within the sidewall of a furnace. The method also includes injecting at least partially during the same time period, a primary combustion material, a secondary combustion material, and a particulate material, into the furnace.

Abstract: A stave cooler used for cooling a furnace wall of a metallurgical furnace such as a blast furnace, having a structure in which cooling pipes to cool a metal base are cast on the side opposite the furnace interior side of the metal base and a heat resistant steel plate having openings or a lamination of heat resistant steel plates having openings is cast, in a prescribed thickness, in the furnace interior side surface of the metal base. It is acceptable to form the lamination suitably into a rectangular parallelepiped and cast it, in a plurality, in the furnace interior side of the metal base. The wear rate of the furnace interior side surface of the stave cooler is small, and its structure prevents the heat resistant steel plate(s) from falling out by thermal expansion of the stave cooler proper or wearing locally.

Abstract: An apparatus and method for cooling the interior wall of an electric arc furnace. The device is an extruded heavy-walled pipe having a base and a fin or plurality of fins. Such pipes are attached to a plate in serpentine fashion and hung on the inside wall of the electric arc furnace above the hearth, thereby forming a cooling surface between the interior and the furnace wall. The fins are sized and arranged to retain splattered slag. The slags solidifies on the pipes, forming an insulation barrier between the molten iron material and the cooling pipes and, consequently, the wall of the furnace.

Abstract: A cooled roof for electric arc furnaces (20) or ladle furnaces (29). The roof being used as a covering element and including a cooling system comprising tubes fed with cooling fluid. The roof including at least a central aperture (25) for the positioning and movement of the electrodes (30) and at least a peripheral aperture (14) for the aspiration and discharge of fumes. The aperture (14) being connected to intake systems. The roof including two single-block cooling structures, inner (1) and outer (12), consisting of respective bent tubes (15, 16) developing according to adjacent and superimposed rings or spirals. The inner (11) and outer (12) cooling structures being associated with one another at least in correspondence with the respective bases facing towards the inside of the furnace (20, 29). Between the inner cooling structure (11) and the outer cooling structure (12) there being defined an annular interspace (13) in which the fumes circulate in an annular direction and slow down.

Abstract: A ceramic fiber block includes a welding stud disposed between two ceramic fiber layers centrally positioned in the ceramic fiber block. The welding stud includes a base stud which at its one end to be welded to a furnace wall and having a ceramic ferrule and at the other end formed with screw threads, an electrode rod having screw threads at its one end in the ceramic fiber block, and first and second nuts connecting the screw threaded ends of the base stud and electrode rod.

Abstract: A method and apparatus for producing crude liquid steel using direct reduced iron as a raw material in an electric arc furnace with an acid resistant sidewall refractory lining. In order to effect the more economical melting operation, the electric arc furnace uses a slag containing a B4 ratio of (lime+magnesia)/(silica+alumina) in the range of about or less than 1.50, resulting in less slag volume, reduced electric power consumption, reduced electrode consumption, and improved iron yield.

Abstract: The furnace vessel for a DC arc furnace has a thermostable wall which preferably consists, in the region situated above the slag line (S), of a plurality of water-cooled wall segments (1) made from steel. These wall segments are fastened to a support structure (13-18). At least one of the wall segments (3) consists of nonmagnetic steel or copper and is preferably arranged on the side of the furnace vessel (5) opposite the power supply device (7). In this way, the influence of the high-current lines which extend below or beside the furnace vessel and cause a deflection of the arc can be compensated.The effect of this nonmagnetic wall segment can be partially or virtually entirely cancelled by a trimming plate (19) which is detachably fastened from the outside to the nonmagnetic wall segment (3), in order in this way to achieve optimum trimming of the deflection of the arc.

Abstract: An energy efficient wall panel for use together with other such panels to extend about selected peripheral portions of a thermal treatment chamber of a high temperature industrial furnace or the like includes a frame that supports an array of elongate cast refractory thermal insulating members 1) that extend side by side, 2) that have relatively wide flange portions that extend substantially contiguously to define a rigid, impact resistant inner surface that faces toward a thermal treatment chamber for absorbing, storing and re-radiating impingent heat energy back into the chamber, 3) that have relatively thin outer portions connected to the supporting frame, 4) that have central web portions that provide needed strength and rigidity while, at the same time, permitting only minimal conductive heat transfer therethrough, and 5) that have elongate, non-cast, fiber-type thermal insulating members compressively sandwiched between adjacent pairs of the cast refractory members for enhancing the panel's insulating c

Abstract: A cooling panel for use in drawing off excess heat from and protecting the side walls and roof of a furnace such as an electric arc furnace, the cooling panel being preferably made entirely out of oxygen-free pure copper. The cooling panel is a wall having a series of strips welded on one side, the strips having recesses on the side adjacent the wall to form channels between the strips and wall for circulating a cooling fluid therethrough. The cooling panel is also provided with inlet and outlet manifolds for supplying and removing the cooling fluid to the passages of the cooling panel. The strips and the manifolds are preferably made using an extruding process and assembled using a tungsten inert gas welding process.

Abstract: A heat shielding cladding for walls, ceilings, or similar surfaces, especially of industrial furnaces, including butted together parallelepipedal modules that are secured to the wall and comprise a plurality of held together and compacted fiber mat webs that are prestressed in a direction parallel to the wall. Adjacent modules are held together in a permanently flexible bond on non-prestressed sides thereof by at least one filamentary, temperature-resistant binder that is guided, without kinking, from a surface of the heat shielding cladding that is remote from the wall to the wall.

Abstract: A graphite block for an induction furnace in the form of a right prism formed from a plurality of plates associated along adjacent end faces parallel to the axis of the prism. Each plate includes a longitudinal recess opening into its top face adjacent a first end and a longitudinal recess opening into its bottom face adjacent an opposite end. Each end face is provided with a flexible graphite joint. The association of plates results from a partial interfitting of a top face longitudinal recess of one plate with a bottom face longitudinal recess of a second plate, the recesses being adapted to leave a void of polygonal section between the plates. This void is occupied by a graphite key of similar section divided over its length into two parts meeting along an oblique surface.

Abstract: A direct current arc furnace, includes a graphite cathode; and a container forming a hearth with a hearth base surface and having a container bottom acting as anode. The container bottom includes a supporting copper-plated sheet steel base consisting of a steel sheet and a copper plating plated on the steel sheet; electrical connection means extending through the steel sheet to contact the copper plating to supply an anode current to the copper plating; and a refractory brick lining having a graphite content above the copper-plated sheet steel base with the copper-plated layer adjacent the brick lining. In a preferred embodiment the graphite content in the brick lining decreases from the vicinity of the copper-plated sheet steel base to the vicinity of the hearth base surface.

Abstract: A furnace lining is formed by a plurality of lining bricks. The bricks have surfaces defining an internal surface of the lining that is to face the interior of the furnace and to receive therefrom radiant heat. At least one depression is formed in the lining and opens onto the surface through an opening. The depression has internal wall surfaces that are geometrically configured to cause radiant heat from the furnace interior that impinges on a first internal wall surface to be reflected thereby and to impinge therefrom onto a second internal wall surface. Thus, the heat will be absorbed by the bricks of the lining, and such heat will be emitted thereby from the inner surface thereof.

Abstract: A furnace for cracking of hydrocarbons, comprising one or several tubes through which the hydrocarbons flow during intensive heating and subsequent cracking. The starting material for the process can be e.g. naphtha or propane, mixed with a small amount of steam. When gases flow through the tube or tubes in the furnace, its temperature is increased up to about 850.degree. C. In order to achieve this, the temperature in the furnace compartment is 1100.degree.-1200.degree. C., and the temperature of the gases in the tubes in the furnace can then exceed 1100.degree. C. The tubes are made from an alloy comprising 15-30 weight % chromium, 3-10 weight % aluminum, the remainder of the composition being mainly iron. This alloy allows significant extension of the possible duration of operation without exchange of the tubes. A further improvement can be achieved by the formation on the inner walls of the tubes of a layer of aluminum oxide, obtained by oxidation of the tubes before the furnace is first used.

Abstract: A lining for a direct-current electric-arc furnace, in which at least part of that regions of said furnace which receives the melt is provided on the inside with an electrically conductive, refractory brick lining and a ring-shaped current conductor, on its outside, constitutes the opposite pole to the upper electrode centrally extending into said surface. The entire bottom area is covered with a refractory, insulating brick lining and a brick lining of graphite bricks is applied onto that brick lining in the radially outer wall region of the furnace. Located adjacent thereto in radially inward manner is an annular zone, comprising an electrically conductive, refractory brick lining. The central bottom area above said insulating brick lining is consittuted by a monolithic ramming mass. Furthermore, the material of the wall of said furnace above said brick lining of graphite bricks largely corresponds to that of said insulating brick lining at the hearth bottom.

Abstract: An electric furnace comprising a container having electrically isolated wall segments useful for melting materials, particlularly ceramics, is disclosed.The electric fornace's side walls are constructed from electrically isolated segments, which cause electric current from a plasma torch to be concentrated on the material in the furnace to be melted rather than diverted to the walls of the furnace.

Abstract: The instant invention relates to the use of hollow silicon carbide beams as refractory in substantially closed open-arc furnaces used for the carbothermic reduction of metal oxides. The silicon carbide beams are used in areas of the furnace which are exposed to temperatures higher than those tolerated by standard refractories, said areas requiring, in addition, stability to oxidation and reduction type chemical reactions and sufficient electrical resistance to minimize arcing from the exposed electrode. In addition, the invention relates to the use of silicon carbide beams in a two-stage, open-arc furnace for the carbothermic reduction of silicon dioxide to silicon metal.

Abstract: An improved electric arc furnace provides increased capacity and reduced operating costs. The furnace has an ob-round shape which locates sidewalls further from the source of heat. The improved furnace can accept a larger scrap charge and provides a larger surface area for slag reactions to take place. All of these advantages are obtained without the need for building new foundations or ancillary equipment.

Abstract: An arc furnace is provided with a variable-capacity ring which is placed at the top of a furnace body and which is split into a plurality of circumferential sections which in turn define in combination a top furnace wall portion, and a driving mechanism for causing the ring to move horizontally. As the ring is moved radially outwardly or inwardly of the furnace body, the height of the furnace body is varied and consequently the capacity or the volume of the furnace body can be varied. As a result, the overcharging of the charge (scrap) is much facilitated; that is, the number of back charges can be reduced. Furthermore, when the pile of the charge in the furnace body is lowered, the capacity or volume of the arc furnace is decreased so that unwanted thermal losses and oxidation and resulting wear of electrodes can be reduced to a minimum.

Abstract: A protective refractory member for protecting heat-absorptive elements in a high-temperature furnace comprises a refractory shape, an interconnected, reticulated metal mesh embedded within the shape and positioned substantially adjacent an inner surface of the shape and at least one opening extending through a thickness of the shape and through the mesh. A tubular insert is located within the opening and is welded to the spirals which define the mesh. Both the insert and certain of the spirals engage the heat-absorptive element and the insert is welded to the element to retain the member thereto.

Abstract: A plasma melting furnace includes one or more plasma burners penetrating the furnace lining, in particular a plasma burner projecting vertically into the interior of the furnace. In order to ensure a most uniform stress on the lining by the heat radiation, the inner surface of the lining is designed to be inclined, converging upwardly.

Abstract: Method of lining a steel-making furnace which comprises lining the bottom area of the furnace with bricks to form a first lining, lining at least a portion of the wall area of the furnace with bricks and/or a water cooling box to form a second lining, lining the first lining and a lower portion of the second lining with a first refractory material, applying a second refractory material to an upper portion of the second lining above the lower portion before heating the furnace, and then heating the second refractory material to cause hardening thereof. The second refractory material comprises magnesium oxide, green chromium oxide, clay, a phosphate, a bisulfate and water. The use of this composition for the second refractory material results in a substantial increase in the durability of the furnace lining.

Abstract: Disclosed is an ore-smelting electrical furnace bath, in which smelting is accomplished with electrodes buried into the melted slag, comprising an externally cooled metallic jacket, a lining forming the walls and the bottom of the bath, and a sealing layer interposed therebetween. The walls of the bath in the melted slag zone are made from graphite-reinforced refractory blocks having a thickness at which the total thermal resistance of these blocks and of the sealing layer ranges from 0.01 to 0.09 m.sup.2 hr.deg./kcal. The lower portion of the aforesaid walls and the bottom are made from refractory carbon blocks.

Abstract: The present invention relates to a reduction furnace with a split furnace body, particularly suited for production of ferro alloys, pig iron or calcium carbide. Furnaces of such types are provided with a furnace pot equipped with an internal refractory lining anchored to the furnace wall by means of anchoring elements. According to the present invention the refractory lining of at least the upper section of the split furnace body comprises a plurality of individual, pre-fabricated elements which are removably arranged at least on the upper section. Each unit comprises preferably a rear plate of steel, pig iron or similar material and one or more anchoring ribs or bolts extending horizontally out from and rigidly secured to the rear plate. The anchoring ribs provide a hold for the refractory lining on the rear plate. The separate units are suspended at least from the upper segment by means of simple support means.

Abstract: The present invention provides a process and apparatus for the production of refractory oxide materials having high fusion points. By high fusion points is meant melting points greater than 2400.degree. C.