This is a national stage application filed under 35 USC 371 based on International Application No. PCT/FI2011/050502 filed May 31, 2011.
The invention relates to a burner arrangement comprising a fluid cooled copper block. Further, the invention relates to a burner assembly, a duct element, a gas circulating duct, and a metallurgical furnace comprising the burner arrangement according to the invention.
A burner is a device to generate a flame to heat up material by combustion of gaseous, liquid or pulverous fuel.
In metallurgical processes burners are used in several different applications, e.g. in gas circulating ducts to provide additional heat to circulating process gas (e.g. US 2009/017409), and in electric arc furnaces as auxiliary heaters to heat and melt metal (e.g. U.S. Pat. No. 6,614,831).
A typical burner arrangement comprises a burner for providing a flame, and an elongated burner channel in close proximity to the burner. The burner channel is configured to form a combustion space and to guide the flame.
US2009/017409 relates to equipment wherein the burner unit is attached directly to the wall of a gas channel and an opening in the refractory wall of the gas channel forms the burner channel.
A problem with this burner arrangement is that the attachment of the burner unit may loosen because the refractory material forming the burner channel tends to deteriorate by cracking due to thermal stresses and/or erosion. Further, erosion of the burner channel weakens its ability to guide the flame into a predetermined direction and to protect the burner unit. It has been tried to solve this problem by providing a cooling coil inside the refractory material defining/forming the burner channel. This arrangement has improved the durability of the burner channel. However, in some installations this is not sufficient. The deterioration of the refractory material of the burner channel may result in damaging the cooling coil which in turn may cause leaking of cooling fluid. Water is usually used as cooling fluid, and leaking of water may cause water-gas explosion inside the furnace. The erosion of the burner channel also weakens its ability to guide the flame into a predetermined direction and to protect the burner unit.
US2009/017409 further relates to a burner unit including a supporting structure that can be fitted as part of the wall of the gas channel. The maintenance of the deteriorated supporting structure requires that the sintering process is interrupted to be able to replace the damaged supporting structure which is a relatively large and heavy part of the gas channel. This causes a relatively long downtime.
U.S. Pat. No. 6,614,831 relates to a burner arrangement for the use in melting furnaces. The burner unit is installed in a fluid-cooled mounting block. The arrangement does not include a burner channel in close proximity to the burner unit and, therefore, the burner unit might get damaged due to blow-back of the flame. Blow-back of the flame to the burner unit may occur if the burner unit is fired at high rates against large pieces of metal scrap that is to be melted in the furnace.
It is an object of the invention to overcome the disadvantages of the prior art as outlined above.
A first aspect of the invention relates to a burner arrangement comprising a burner unit for providing a flame, and an elongated burner channel in close proximity to the burner unit, the burner channel forming a combustion space being configured to protect the flame and the burner unit. According to the invention the burner arrangement comprises a fluid cooled copper block, preferably a water cooled copper block, including a cooling conduit for circulation of the cooling fluid, preferably water, a first end to which the burner unit is releasably attached, and a second end, and the burner channel extends inside the fluid cooled copper block from the first end to the second end.
A second aspect of the invention relates to a burner assembly comprising the burner arrangement according to the invention and a refractory structure which is made of castable refractory material and to which the burner arrangement is connected, preferably releasably connected.
In one embodiment, the burner assembly comprises
In one embodiment of the burner arrangement and burner assembly, the diameter of the burner channel increases in the direction to the second end. For example, if the burner arrangement is installed in a gas duct of a strand sintering furnace or steel belt sintering furnace, as the diameter of the burner channel increases in the direction to the gas circulating duct the diameter of the burner channel decreases in the direction to the burner unit. This provides protection of the burner flame from the gas flowing in the duct.
In one embodiment of the burner arrangement and burner assembly, the cross section of the burner channel is circular.
In one embodiment of the burner arrangement and burner assembly, the cooling conduit has an inlet for introducing the cooling fluid to the cooling conduit, and an outlet for exiting of the cooling fluid from the cooling conduit, said inlet and outlet are located at the outer periphery of the copper block adjacent to the first end, and a coil section extending between the inlet and the outlet, said coil section being arranged to surround the burner channel.
In one embodiment of the burner arrangement and burner assembly, the burner unit comprises a connecting flange to attach the burner unit to the first end of the fluid cooled copper block through a bolted joint.
In one embodiment of the burner arrangement and burner assembly, the burner arrangement comprises a tubular mounting sleeve, which is preferably made of metal such as steel or mild steel, wherein the tubular mounting sleeve comprises anchor elements on the outer surface of the tubular mounting sleeve for anchoring the tubular mounting sleeve in a castable refractory material, and that the tubular mounting sleeve is adapted to receive the fluid cooled copper block inside the tubular mounting sleeve.
In one embodiment of the burner arrangement and burner assembly, the outer surface of the fluid cooled copper block is slightly conical because the outer surface of the copper block converges in the direction to the second end, i.e. its outer diameter decreases in the direction to the second end. In one embodiment of the burner arrangement and burner assembly, the inner surface of the tubular mounting sleeve has a conical shape corresponding to the shape of the outer surface of the copper block.
In one embodiment of the burner arrangement and burner assembly, the burner arrangement further comprises a ring-like connecting element for attaching the fluid cooled copper block to the tubular mounting sleeve.
In one embodiment of the burner arrangement and burner assembly, the ring-like connecting element comprises a first flange to attach the ring-like connecting element to the first end of the copper block through a bolted joint and a second flange to attach the ring-like connecting element to the mounting sleeve through a bolted joint.
In one embodiment of the burner assembly, the burner assembly comprises a tubular mounting sleeve which is preferably made of metal such as steel or mild steel provided with anchor elements on the outer surface of the tubular mounting sleeve for anchoring the mounting sleeve to the castable refractory structure, and the tubular mounting sleeve is adapted to receive the fluid cooled copper block inside the tubular mounting sleeve.
In one embodiment of the burner assembly, the burner arrangement further comprises a ring-like connecting element for attaching the fluid cooled copper block to the tubular mounting sleeve.
In one embodiment of the burner assembly, the refractory structure is a part of a channel wall of a gas duct, such as a wall of a gas circulating duct of a strand sintering furnace or steel belt sintering furnace.
In one embodiment of the burner assembly, the refractory structure is a refractory wall, or part of a refractory wall, of a metallurgical furnace, such as an electric arc furnace.
A third aspect of the invention relates to a duct element. The duct element according to the invention comprises a burner assembly according to the invention, wherein the refractory structure is a refractory block having a wall made of refractory material, preferably castable refractory material, said wall including a mounting sleeve for the burner arrangement, and complementary sector element which is releasably attached to the refractory block to form a tubular or ring-like structure together with the refractory block.
In one embodiment of the duct element, the refractory block comprises first connecting means for connecting the refractory block to the complementary sector element and second connecting means for connecting the refractory block to adjacent elements of a duct.
In one embodiment of the duct element, the complementary sector element comprises third connecting means for connecting the complementary sector element to the first connecting means of the refractory block, and fourth connecting means for connecting the complementary sector element to adjacent elements of the gas circulating duct.
In one embodiment of the duct element, the first connecting means, the second connecting means, third connecting means and/or the fourth connecting means comprise flanges provided with bolt holes to attach the refractory block and the complementary sector element to each other and to the adjacent elements of the duct through bolted joints.
A fourth aspect of the invention relates to a gas circulating duct, preferably a gas circulating duct of a strand sintering furnace, preferably a steel belt sintering furnace, comprising a burner arrangement according to the invention, a burner assembly according to the invention, or a duct element according to the invention.
A fifth aspect of the invention relates to a metallurgical furnace comprising a burner arrangement according to the invention, a burner assembly according to the invention, a duct element according to the invention, or a gas circulating duct according to the invention. In case that the metallurgical furnace is a strand sintering furnace or a steel belt sintering furnace, it may contain a burner arrangement, a burner assembly, a duct element or a gas circulating duct. In case that the metallurgical furnace is a melting furnace, such as an electric arc furnace, it may contain a burner arrangement or a burner assembly, but it preferably does not contain a duct element or a gas circulating duct.
Another embodiment of the invention relates to a metallurgical furnace comprising the burner arrangement in the burner assembly according to the invention.
A sixth aspect of the invention relates to a method for maintenance of the burner arrangement. The method comprises a step of detaching the burner unit from the fluid cooled copper block.
Another embodiment of the invention relates to a method for maintenance of a burner arrangement in a burner assembly according to the invention. The method comprises steps of removing the burner arrangement by pulling the fluid cooled copper block out from the mounting sleeve, and installing a new burner arrangement by inserting the fluid cooled copper block into the mounting sleeve.
Another embodiment of the invention relates to a method for maintenance of a gas circulating duct according to the invention to replace the burner unit. The method comprises the steps
Another embodiment of the invention relates to a method for maintenance of a gas circulating duct according to the invention to replace the refractory block. The method comprises the steps
Another embodiment of the invention relates to a method for maintenance of a gas circulating duct according to the invention to replace the complementary sector element. The method comprises steps
The invention provides many advantages. If the refractory around the burner opening is deteriorating, e.g. due to erosion or thermal stress, the fluid cooled copper block would not be damaged and optimal flow of the flame would be ensured. Thereby, the performance of the burner unit is ensured. The fluid cooled copper block is removable and, thus, there is no need to remove parts or a large block of the surrounding refractory material for maintenance. This will reduce maintenance downtime. A more uniform temperature profile is achieved in the refractory material as compared to having steel coils inside the refractory material because the fluid cooled copper block is surrounded by a tubular mounting sleeve. Further, damage to the cooling conduit is less likely to occur because the cooling conduit is located inside the fluid cooled copper block and the copper is surrounded by a metal sleeve, preferably a steel sleeve or mild-steel sleeve, hence, protecting the cooling conduit. The burner unit is located at the first end of the fluid cooled copper block, so that the burner flame is not interfered with by gas travelling in the gas duct. In case the burner arrangement is installed in the side wall of a melting furnace, the fluid cooled copper block with the burner channel protects the burner unit from flame blow-back. Further, replacement of the burner unit and/or the fluid cooled copper block is facilitated.
For the purpose of this description, the terms “refractory material” and “castable refractory material” stand preferably for refractory cement or refractory cement castable such as alumina low cement castable, more preferably alumina low cement castable comprising steel fibres or low cement alumina silica castable comprising steel fibres.
The accompanying drawings, which are included to provide a better understanding of the invention constitute part of the description, illustrate preferred embodiments of the invention and help to explain the principles of the invention.
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The refractory block 16 forms a part of the duct wall 17 of the gas circulating duct 18a. The arrows show the direction of the gas flow. The burner arrangements B are arranged so that the burner channels 2 of the fluid cooled copper block 3 direct the flame F substantially to the direction of the gas flow in the gas circulating duct 18a. Due to the angled arrangement of the burner arrangements B the burner unit 1 and burner channel 2 are well protected from the influences of the gas flow.
The refractory block 16 comprises first connecting means 39 for connecting the refractory block 16 to the complementary sector element 33 and second connecting means 40 for connecting the refractory block 16 to adjacent elements of the gas circulating duct 18a, 18b. The complementary sector element 33 comprises third connecting means 41 for connecting the complementary sector element 33 to the first connecting means 39 of the refractory block 16, and fourth connecting means 42 for connecting the complementary sector element 33 to adjacent elements of the gas circulating duct 18a, 18b. The first connecting means 39 comprise flanges with bolt holes 43 to attach the refractory block 16 to the complementary sector element 33, preferably through bolted joints. The third connecting means 41 comprise flanges with bolt holes 43 to attach the complementary sector element 33 to the refractory block 16, preferably through bolted joints. The second connecting means 40 comprise flanges with bolt holes 43 to attach the refractory block 16 to the adjacent elements of the gas circulating duct 18a, 18b, preferably through bolted joints. The fourth connecting means 42 comprise flanges with bolt holes 43 to attach the complementary sector element 33 to the adjacent elements of the gas circulating duct 18a, 18b, preferably through bolted joints.
For maintenance of a gas circulating duct 18a, to replace the burner unit 1, the refractory block 16 having the burner arrangement B attached therein is detached from the complementary sector element 33 and from the gas circulating duct 18a, 18b. Thereafter, the burner unit 1 to be replaced is detached from the fluid cooled copper block 3 which remains attached to the refractory block 16. A new burner unit 1 can then be attached to the cooled copper block 3. Alternatively, the burner arrangement B in which the burner unit 1 and the fluid cooled copper block 3 are connected to each other as an assembly can be detached from the refractory block 16 and thereafter the burner unit 1 is detached from the fluid cooled copper block 3, and a new burner unit 1 is attached to the cooled copper block 3. Finally, the refractory block 16 having the burner arrangement B attached therein can be attached to the complementary sector element 33 and to the gas circulating duct 18a, 18b.
For maintenance of a gas circulating duct 18a, to replace the refractory block 16, the refractory block 16 to be replaced having the burner arrangement B attached therein is detached from the complementary sector element 33 and from the gas circulating duct 18a, 18b. Thereafter, the burner arrangement B is detached from the refractory block 16. The burner arrangement B is attached to a new refractory block 16. Finally, g the refractory block 16 having the burner arrangement B attached therein is attached to the complementary sector element 33 and to the gas circulating duct 18a, 18b.
For maintenance of a gas circulating duct 18a, to replace the refractory block 16, to replace the complementary sector element 33, the refractory block 16 having the burner arrangement B attached therein is detached from the complementary sector element 33 and from the gas circulating duct 18a, 18b. The complementary sector element 33 to be replaced is detached from the gas circulating duct 18a, 18b. A new complementary sector element 33 is attached to the gas circulating duct 18a, 18b. Finally, the refractory block 16 having the burner arrangement B attached therein is attached to the complementary sector element 33) and to the gas circulating duct 18a, 18b.
It is obvious to a person skilled in the art that with the advancement of technology, the basic idea of the invention may be implemented in various ways. The invention and its embodiments are thus not limited to the examples described above; instead they may vary within the scope of the claims.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/FI2011/050502 | 5/31/2011 | WO | 00 | 11/26/2013 |
Publishing Document | Publishing Date | Country | Kind |
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WO2012/164142 | 12/6/2012 | WO | A |
Number | Name | Date | Kind |
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1163650 | Fogler | Dec 1915 | A |
3615249 | Martois | Oct 1971 | A |
5149261 | Suwa et al. | Sep 1992 | A |
6190158 | Legiret | Feb 2001 | B1 |
6238206 | Cummings, III | May 2001 | B1 |
6372010 | Shver et al. | Apr 2002 | B1 |
6422858 | Chung | Jul 2002 | B1 |
6461145 | Giraud | Oct 2002 | B1 |
6614831 | Shver | Sep 2003 | B2 |
7497682 | Kaczenski | Mar 2009 | B2 |
20090017409 | Santala et al. | Jan 2009 | A1 |
Number | Date | Country |
---|---|---|
2280501 | Feb 1995 | GB |
9814741 | Apr 1998 | WO |
0160123 | Aug 2001 | WO |
2007104828 | Sep 2007 | WO |
Entry |
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International Search Report, PCT International App. No. PCT/FI2011/050502, filed May 31, 2011, Outotec Oyj, 4 pgs. |
Number | Date | Country | |
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20140099587 A1 | Apr 2014 | US |