A method of charging a pre-packaged charge in a metallurgical or refining furnace includes providing a disposable metal container having at least one attachment member and forming a pre-packaged charge by loading scrap material into the metal container. The method also includes releasably coupling the at least one attachment member of the container to a lifting device, and then de-coupling the pre-packaged charge from the lifting device so that the combination of the scrap material and the disposable metal container are charged in the furnace.

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.

One embodiment is a cooling system for regulating temperature of a surface of a metallurgical furnace. The cooling system includes a plurality of spray conduits. Each spray conduit has one or more control valves and has a plurality of nozzles. A plurality of temperature sensors are disposed proximate the surface of the metallurgical furnace. A control system adjusts the control valves of the plurality of spray conduits in response to temperature information derived from the plurality of temperature sensors.

One embodiment is a cooling system for regulating temperature of a surface of a metallurgical furnace. The cooling system includes a plurality of spray conduits. Each spray conduit has one or more control valves and has a plurality of nozzles. A plurality of temperature sensors are disposed proximate the surface of the metallurgical furnace. A control system adjusts the control valves of the plurality of spray conduits in response to temperature information derived from the plurality of temperature sensors.

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.

A system used in monitoring one or more operating parameters of a coolant-fluid cooled industrial installation includes one or more an acoustic sensors positioned to receive and sense one or more acoustic signals in an installation coolant-fluid flow. The acoustic sensor assembly operates to emit and sense acoustic signals at frequency ranges above and/or below the background noise frequency ranges which are associated with the normal industrial installation operation. Output data signals representative of sensed acoustic signals are compared to target frequency profiles predetermined as representing an acoustic frequency associated with a predetermined installation operating parameter or event.

A method for providing a region of inert gas around the electrodes in an electric arc furnace is provided. This electric arc furnace includes consumable graphite electrodes, a melting zone, and at least one lance including an inlet and an outlet, wherein the inlet is connected to a liquid inert fluid source. The method includes introducing the consumable graphite electrodes into the melting zone, wherein the distal ends of the electrodes form arcs with a solid charge of scrap metal. The method also includes introducing the liquid inert fluid into the inlet end of the at least one lance, wherein the inert fluid exits the outlet end and is introduced into the melting zone proximate to the distal ends of the electrodes, thereby providing an inert gaseous blanket, once the liquid vaporizes, around the distal ends of the electrodes

A method of starting a molten bath-based process for smelting a metalliferous material is disclosed. The method includes using the heat flux of water-cooled elements in lower parts of a smelting vessel to provide an indication of molten bath temperature during at least an early part of the start-up method and adjusting injection rates of oxygen-containing gas and/or carbonaceous material into the smelting vessel to control the molten bath temperature during start-up without exceeding critical heat flux levels and tripping the start-up method.

A method of starting a molten bath-based process for smelting a metalliferous material is disclosed. The method includes using the heat flux of water-cooled elements in lower parts of a smelting vessel to provide an indication of molten bath temperature during at least an early part of the start-up method and adjusting injection rates of oxygen-containing gas and/or carbonaceous material into the smelting vessel to control the molten bath temperature during start-up without exceeding critical heat flux levels and tripping the start-up method.

A method for forming a protective antioxidative barrier on the furnace electrodes using a chemically altered cooling liquid containing an antioxidant additive. This method can be applied to electrodes used in electric arc furnaces and ladle metallurgy furnaces. The method can involve spraying the cooling liquid onto the electrode, thereby forming the protective antioxidative barrier and reducing the oxidation of the electrode.