Abstract: The present disclosure describes a metal making burner in fluid communication with a gas inlet and comprising an oxygen inlet valve that provides control of oxygen flow to two different discharge lines, such as a main line and a shroud line. This allows distinct “modes” of operation, utilizing only the flow from the single oxygen supply as the control method. The apparatus includes a moving piston with ports therein that meter flow to both discharge lines when the ports line up with a separate set of ports in a cylinder that receives the piston. At low or no pressure from the gas inlet, flow rates follow one ratio of flows between the discharge lines. As pressure from a gas inlet changes in the burner, the piston moves and realigns the ports (opening or closing some of the ports), which results in a different ratio of flows between the discharge lines.

Abstract: A furnace stave comprising a plurality of internal channels or conduits for circulating cooling fluid through the stave; an inlet and an outlet channel associated with each internal channel or conduit; wherein one of the internal channels or conduits is disposed in a protrusion from the stave.

Abstract: A burner, comprising: an oxygen supply tube and a burner tip defining a concave face; wherein the burner tip defines a main oxygen nozzle having a parabolic shape.

Abstract: A water cooled box to be installed in the side wall of a metal making furnace to hold and protect implements such as a burner, a lance, or a material (i.e., carbon or lime) injection device. The box preferably comprises a copper outer shell and a steel inner shell liner welded together, whereby a chamber is formed through which cooling water passes. The box further comprises an inlet and outlet for the water flow and a plurality of conduit passages between the copper and steel shells for mounting the aforementioned implements. The copper shell has bars or slots for slag retention and the steel shell has means for mounting the box into the furnace wall. The copper shell is formed into a curved U-shape for preventing cracking due to thermal mechanical stress and to raise the natural frequency of the panel to resist vibration which can also cause cracking.

Abstract: A fluid assisted particle injector for a metallurgical furnace, comprising: an injector tube having an entrance end, an exit end and a removable tip; a cover tube disposed over the injector tube; a fluid and particle injector port in line with the longitudinal center axis of the injector tube and a secondary fluid port for directing pressurized fluid over the outside of the injector tube and within the cover tube; the injector tube defining a tapered internal bore having a particle entrance end and a particle exit end, wherein the diameter of the particle exit end is smaller than the diameter of the particle entrance end.

Abstract: A fluid cooled housing system for use in metal making furnaces. In particular, the present invention related to a novel and inventive housing and guard member configured to receive and protect an implement, such as a burner or a lance, used in connection with metal making furnaces. A preferred embodiment of the present invention comprises a housing comprising an outer shell and an inner shell that define a fluid chamber, an end cap, a bushing insert, a face plate, a fluid inlet, and a fluid outlet. Both the fluid inlet and the fluid outlet are preferably in fluid communication with both the fluid chamber defined by the shells and a fluid chamber defined by the bushing insert. In alternative preferred embodiments, the housing system further comprises a guard member that preferably envelopes and further protects the fluid cooled housing.

Abstract: The present invention preferably comprises a system and method for measuring and/or continuously monitoring the temperature and/or height of a molten metal bath in a vessel. Specifically, an ultrasonic transmitter and an ultrasonic receiver are disposed about sides of the vessel and are used to send and receive an ultrasonic signal in order to detect the temperature of the bath. More specifically, the ultrasonic transmitter is configured to send an ultrasonic signal through the vessel, and the ultrasonic receiver is configured to receive that ultrasonic signal after it has travelled through the vessel (comprising the molten metal bath). The ultrasonic receiver provides at least one signal to a processing unit (i.e., control center), which processes the at least one signal to determine the temperature and/or level of the molten metal bath. The invention may further comprise chillers to protect the transmitter and receiver from the heat of the bath.

Abstract: A lance comprising a lance body including a lance head connected to said lance body and comprising a nozzle body having a central strut having bore hole; a camera assembly, such as an optical or infrared camera assembly, received in said bore hole for monitoring the temperature of said lance head or molten heat in which the lance is inserted; and a protective pipe pressurized with a gas disposed in the bore and surrounding said camera assembly.

Abstract: A stave comprising an outer housing, an inner pipe circuit comprising individual pipes housed within the outer housing, wherein the individual pipes each has an inlet end and an outlet end and wherein each pipe may or may not be mechanically connected to another pipe, and a manifold, integral with or disposed on or in the housing; wherein the inlet and/or outlet ends of each individual pipe is disposed in or housed by the manifold. The manifold may be made of carbon steel while the housing may be made of copper. Each of the inlet and outlet ends of each individual pipe may be surrounded in part by cast copper within a housing of the manifold.

Abstract: A furnace stave comprising a plurality of internal channels or conduits for circulating cooling fluid through the stave; an inlet and an outlet channel associated with each internal channel; wherein the inlet channels of two internal channels are fed by the same inlet pipe or conduit. In another preferred aspect, the inlet channels of two internal channels fed by the same inlet pipe or conduit may or may not be overlapping or in fluid communication with each other.

Abstract: The present disclosure relates in general to a furnace apparatus and in particular to a system including a method and apparatus for detecting leaks in fluid-cooled panels, burner housings, and/or any fluid cooled component for industrial furnaces such as metal smelting furnaces, blast furnaces, electric arc furnaces (EAFs) or the like.

Abstract: A stave comprising a housing, an inner cooling fluid circuit comprising a cooling fluid inlet, a cooling fluid outlet and one or more cooling fluid pipes housed within, or cooling fluid passageways defined by, the housing, wherein each cooling fluid pipe and/or passageway is in direct or indirect fluid communication with the cooling fluid inlet and the cooling fluid outlet; and a manifold, integral with or disposed on or in the housing, that provides support for installation of the stave on a furnace shell; wherein the manifold has one or more inlet pipes, or defines one or more inlet passageways, for providing cooling fluid to the cooling fluid inlet of the cooling fluid circuit of the housing; and wherein the manifold has one or more outlet pipes, or defines one or more outlet passageways, for receiving cooling fluid from the cooling fluid outlet of the cooling fluid circuit of the housing.

Abstract: A pneumatic drilling device comprising: an impact manifold or cylinder in fluid communication with a rotary air manifold or gear box; and a single air inlet. The single air inlet may be in fluid communication with the impact manifold or cylinder.

Abstract: An oxygen blowing lance comprising: a lance body including an oxygen conduit and cooling water inlet and outlet conduits surrounding said oxygen conduit; a lance head connected to said lance body and comprising a nozzle body, said nozzle body including a central strut having bore hole, a plurality of nozzles arranged about said central strut, and a plurality of cooling chambers arranged about said central strut, wherein said plurality of nozzles are in fluid communication with said oxygen conduit for discharging oxygen from said oxygen conduit onto a metal bath in a converter vessel, and wherein said plurality of cooling chambers are in fluid communication with said cooling water inlet and outlet conduits; a temperature probe or camera assembly received in said bore hole for monitoring the temperature of said lance head or molten heat in which the lance is inserted; signal lines connected to said temperature probe for conveying signals from said temperature probe whereby operation of said blowing lance is reg

Abstract: A furnace stave comprising a plurality of internal channels or conduits for circulating cooling fluid through the stave; an inlet and an outlet channel associated with each internal channel or conduit; wherein one of the internal channels or conduits is disposed in a protrusion from the stave.

Abstract: A distributor for a post-combustion lance, comprising: an annular member, an inner reinforcing sleeve and an outer sleeve, wherein the inner reinforcing sleeve defines a plurality of first openings and the annular member defines a plurality of second openings, wherein each of the first and second openings is in fluid communication, directly or indirectly, with a first cooling fluid passageway of the lance. Each of the first openings may be contiguous with and in direct fluid communication with one of the second openings. Additionally, the annular member may define a plurality of third openings, wherein each of the third openings is in fluid communication with a second cooling fluid passageway of the lance.

Abstract: An oxygen blowing lance comprising: a lance body including an oxygen conduit and cooling water inlet and outlet conduits surrounding said oxygen conduit; a lance head connected to said lance body and comprising a nozzle body, said nozzle body including a central strut having bore hole, a plurality of nozzles arranged about said central strut, and a plurality of cooling chambers arranged about said central strut, wherein said plurality of nozzles are in fluid communication with said oxygen conduit for discharging oxygen from said oxygen conduit onto a metal bath in a converter vessel, and wherein said plurality of cooling chambers are in fluid communication with said cooling water inlet and outlet conduits; a temperature probe or camera assembly received in said bore hole for monitoring the temperature of said lance head or molten heat in which the lance is inserted; signal lines connected to said temperature probe for conveying signals from said temperature probe whereby operation of said blowing lance is reg

Abstract: A stave/brick construction, comprising: a stave having a plurality of ribs and a plurality of channels, wherein a front face of the stave defines a first opening into each of the channels; a plurality of bricks wherein each brick is insertable into one of the plurality of channels via its first opening to a position, upon rotation of the brick, partially disposed in the one channel such that one or more portions of the brick at least partially engage one or more surfaces of the one channel and/or of a first rib of the plurality of ribs whereby the brick is locked against removal from the one channel through its first opening via linear movement without first being rotated; and one or more wear monitors and/or thermocouples, wherein each wear monitor and thermocouple is disposed through or adjacent to the stave and/or one or more of the bricks.

Abstract: A frame/brick and/or a stave/brick construction, having a frame having a plurality of ribs and a plurality of channels, wherein a front face of the frame defines a first opening into each of the channels, and a plurality of bricks wherein each brick is insertable into one of the plurality of channels via its first opening to a position, upon rotation of the brick, partially disposed in the one channel such that one or more portions of the brick at least partially engage one or more surfaces of the one channel and/or of a first rib of the plurality of ribs whereby the brick is locked against removal from the one channel through its first opening via linear movement without first being rotated.

Abstract: Pipe fractures in cooling staves of blast furnaces are a common failure mechanism Herein is a repair method for a cooling stave utilized in a blast furnace, the cooling stave having a compromised stave inlet outlet pipe attached to the cooling pipe in the cooling stave, the method comprises of the steps of inserting a rigid pipe into the compromised stave inlet outlet pipe to form a first annulus; inflating a bladder disposed inside the inner pipe and cooling stave; injecting a first uncured epoxy material into the first annulus; permitting the first uncured epoxy to cure; and removing the bladder.