The consumption of refractories and electricity must also increase, along with the rising labor intensity for workers. Since we primarily produce steel, it's not feasible to quickly repair the furnace lining using a high-temperature furnace body after the molten steel is poured, as is common in regular smelting operations. Therefore, before opening the furnace without high-temperature sintering, the lining must be repaired. When erosion becomes severe, repairs are necessary, and after each repair, a large amount of firewood and electric baking is required. Despite this, the furnace can only process one heat at a time.
For a long time, this process has led to significant waste of refractory materials and electricity, while increasing the workload for workers. To address this, we conducted trials and discussions on how to reduce slag line erosion, but the results were limited. Every time a hot spot was repaired, a large portion of the slag line had to be removed. In response, we shifted our focus to testing high-temperature hot spots. By introducing a partial water-cooling box, we achieved some improvement. Later, we extended local water cooling to key areas, including the slag line. After multiple smelting cycles, the effect became noticeable, and the number of minor repairs gradually decreased. Initially, we had one repair per heat, but now it's reduced to one repair every two heats—possibly even more.
Based on the current erosion conditions of the furnace wall, with proper ingredients and careful operation, along with adequate protection for the water-cooled sections, there is still room for further improvement. Not only have working conditions for staff improved, but the consumption of refractories has also dropped significantly. One concern when using water-cooling boxes is whether they increase heat loss and delay the materialization reaction inside the furnace. However, based on theoretical analysis and practical results, we believe that steelmaking is a high-temperature process, and the lining must operate above 1500°C. During the melting phase, the charge absorbs a lot of heat. Once the well is drilled, the arc remains surrounded by scrap for an extended period.
During the oxidation phase, the molten steel experiences intense boiling and endothermic conditions, resulting in relatively low heat loss. The radiation from the arc and molten pool surface on the furnace wall and roof is reduced. In the reduction phase, the molten steel is very hot, and the slag, which has good fluidity, reflects the arc light effectively, directly radiating onto the lining. This increases the thermal load on the lining. At this stage, the heat loss from the water-cooled system is minimal, mostly radiant heat. For the entire smelting process, the temperature difference change has little impact, so it does not delay the materialization reaction in the furnace.
We calculated the electricity consumption before and after the use of water cooling. The results showed that the electricity consumption per ton of molten steel was reduced after implementing water-cooled tanks. Practical experience proves that water cooling on the lower part of the furnace wall has a negligible effect on the smelting temperature. Additionally, it significantly reduces the high slag content caused by the leaching of slag line refractories. Poorly flowing slag leads to increased inclusions in the steel and a decline in steel quality.
Using water cooling on the lower part of the furnace wall is the most effective way to enhance heat dissipation, lower the hot spot temperature, reduce the thermal load on the furnace wall, and is a fundamental measure to extend the furnace's service life. According to preliminary estimates, if repairs are performed on an as-needed basis and minor repairs are repeated several times, each baking in the mid-renovation oven could save nearly RMB 10,000. This saves a considerable amount of money for the country.
As the number of orders increases, the economic benefits will continue to grow. Therefore, this design is reasonable. However, at this point, measuring the combustion chamber volume using the cup titration method introduces errors due to the titration itself, making it difficult to achieve the required accuracy. Measuring the volume between the calculated and labeled values is challenging. The introduction of the above formula, especially the development and application of pots, spears, and similar tools, greatly facilitates the control and measurement of such combustion chambers. We hope this formula can serve as a reference for manufacturers in the same industry and related host companies.
The determination of dimensional tolerances enables accurate calculation of the combustion chamber volume through the derivation of the above formula. This allows us to precisely define the allowable machining tolerances for the combustion chamber. In actual processing and measurement, as long as the size and shape tolerances are maintained, the combustion chamber volume can be guaranteed, rather than relying on inaccurate cup titration measurements.
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