Described herein is a sidewall suitable for use in a metallurgical furnace, and metallurgical furnace having the same. The sidewall has an upper wall, an outer wall coupled to an outer side of the upper wall, and extending downward from the outer wall. A sloped wall is coupled to an inner side of the upper wall. The sloped wall extends downward and inward from the upper wall. The sloped wall has a first surface facing the outer wall and a second surface facing a centerline of the sidewall. A spray cooling assembly is disposed between the sloped wall and the outer wall. The spray cooling assembly is configured to spray coolant on the first surface of the sloped wall.

Described herein is a sidewall suitable for use in a metallurgical furnace, and metallurgical furnace having the same. The sidewall has an upper wall, an outer wall coupled to an outer side of the upper wall, and extending downward from the outer wall. A sloped wall is coupled to an inner side of the upper wall. The sloped wall extends downward and inward from the upper wall. The sloped wall has a first surface facing the outer wall and a second surface facing a centerline of the sidewall. A spray cooling assembly is disposed between the sloped wall and the outer wall. The spray cooling assembly is configured to spray coolant on the first surface of the sloped wall.

The present document describes a smelting apparatus for smelting metallic ore. The smelting apparatus comprises a furnace having a continuous curved wall and end walls defining a longitudinal volume having a longitudinal axis in a horizontal direction. The continuous curved wall has a lowermost area. The longitudinal volume is divided in at least three longitudinal layers comprising a top layer within which gasified fuel is combusted for creating a hot gas composition at a temperature sufficient to release, from the metallic ore, at least molten metal and slag, a lowermost layer at the lowermost area for holding molten metal, and a mid-layer above the lowermost layer in which the slag accumulates. The present document also describes processes using the smelting apparatus for producing ferrous and non-ferrous minerals from a metallic ore.

The present document describes a smelting apparatus for smelting metallic ore. The smelting apparatus comprises a furnace having a continuous curved wall and end walls defining a longitudinal volume having a longitudinal axis in a horizontal direction. The continuous curved wall has a lowermost area. The longitudinal volume is divided in at least three longitudinal layers comprising a top layer within which gasified fuel is combusted for creating a hot gas composition at a temperature sufficient to release, from the metallic ore, at least molten metal and slag, a lowermost layer at the lowermost area for holding molten metal, and a mid-layer above the lowermost layer in which the slag accumulates. The present document also describes processes using the smelting apparatus for producing ferrous and non-ferrous minerals from a metallic ore.

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.

Disclosed herein is a metallurgical furnace and roof having a drain system. The roof has a roof body comprising a top surface having a center opening, a bottom surface opposite the top surface, and an outer sidewall connecting the top surface to the bottom surface. The outer sidewall, the bottom surface and the top surface define an interior portion. An internal spray cooling system is disposed in the interior portion of the body. A drain system is integral with the body. The drain system has a roof evacuation conduit disposed outside the interior portion and configured to collect spay coolant from the interior portion of the body. The drain system additionally has a drain box having a vent and an exit pipe, wherein the roof evacuation conduit channels spent coolant by gravity into the drain box which is evacuated under gravity by the exit pipe.

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.

A cooling assembly for a metallurgical furnace includes a cooling plate disposed inside of a furnace shell of the metallurgical furnace; a cooling pipe traversing a shell opening in the furnace shell and being connected to the cooling plate; and a compensator disposed around the cooling pipe for forming a seal between the cooling pipe and the furnace shell.

In order to provide ways for facilitating repair of a cooling system of the metallurgical furnace, the method includes at least the step of performing at least one cutting operation with a cutting device having a fixture and a cutting tool movably connected to the fixture for a guided movement with respect to the fixture. The fixture is mounted to the cooling pipe, whereby the cutting device is aligned with respect to the cooling pipe, and the cutting tool is guidedly moved while performing the cutting operation.

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.