Replacing the cast iron stave with a commercial density cooling plate requires replacement of the furnace shell because there is no considerable effort and associated expense. A typical cooling plate cannot fit into the open structure of a cooled fireplace shell. In most cases, this furnace shell must be reinforced to support the cooling plate. This type of overhaul is used on blast furnaces with a high proportion of pellets in the charge where cast iron staves are not satisfactory. Replacing a Conventional Cooling Plate with a Cooling Wall If a cooling wall pipe can be connected to a current cooling plate, replacing the cooling plate with a cooling wall can be considered. The M-potassium copper stave can be designed with sufficient flexibility for the cooling water pipe to be of sufficient geometry, which can also be considered.
The two main reasons for replacing the cooling plate with the cooling wall are to reduce the shutdown time and increase the working volume. The significant increase in investment costs was mainly due to the fact that the cost of copper and cast iron staves exceeded the cost of optimized slab cooling refractory materials. Moreover, due to the inconsistent cooling water and water pipe system requirements, major improvements have been made during the inspection process to remove the existing cooling system from the blast furnace. However, the installation of cooling staves can save considerable downtime and work on site, thus making the turnaround time faster, which significantly reduces inspection time.
The microstructure of the cast copper body and the cast Monel tube after casting has increased its design possibilities. This has been applied for many years in the design of non-ferrous metallurgical furnaces, and its application range can be broader. Horizontal furnace cooling plates can also use Monel tubes as cooling water channels. The same method can be applied to tuyere and tuyere coolers. Potassium-copper cooling stave can also be developed to the lower part of the blast furnace, making the furnace cooling stave.
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