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.

One or more embodiments of a burner panel for a metallurgical furnace is described herein. The burner panel has a body having a top surface, a bottom surface, a left surface, a right surface, and a front surface surrounding an interior burner area. A spray-cool system disposed in the interior area. A burner tube at least partially disposed in the interior burner area and extends into the front surface. The burner tube is configured to accept a burner.

An evaporative cooling system for a scrap metal furnace with an afterburner, a rotary kiln and a conveyor that loads scrap metal into the kiln. Pressurized water runs through water lines to two water spray subassemblies. The first subassembly sprays atomized water into a heating duct between the afterburner and a gas recycle return duct. The second subassembly sprays water onto the scrap metal on the conveyor. Water flow through the subassemblies is regulated by one or more water flow controllers, pumps and/or flow sensors, which may be computer controlled. A water heater warms the water to a desired temperature.

Systems and methods for cooling a graphite furnace electrode with manufactured spray cooling water for high-temperature furnace electrodes. The manufactured spray cooling water can be engineered to have desired properties and/or components that improve sidewall oxidation losses. The manufactured spray cooling water can be produced by modifying a water source that is used to cool the electrodes to provide a more pure water and optionally adding an additive to the more purified water.

Methods and systems are described for evaluating the coverage of cooling water that is sprayed onto the surface of a graphite furnace electrode. The surface of the electrode can be sprayed with cooling water that includes an additive, and the sprayed surface can be visually inspected or imaged to assess the cooling water coverage of the electrode surface. One or more corrective measures can be taken to improve the spray coverage if it is deemed to be inadequate.

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.

An apparatus is disclosed for a split spray-cooled roof for a tilting metallurgical furnace. The split spray-cooled roof has a center, a first hollow metal roof section and a second hollow metal roof section. The first and second hollow roof sections are attached together along a prescription split line. The prescription split line having a first split line and a second split line, wherein the first split line is not aligned with the second split line and wherein the first and second split line are not aligned with the center.

Methods and systems are described for measuring and evaluating the consumption of graphite electrodes that are used to melt raw materials in furnaces. A dimension of a tapered region of the electrode can be measured, e.g., with a laser distance measuring instrument, and the volume loss of the electrode can be calculated based on the measured dimension. One or more corrective actions can be taken to reduce the electrode consumption losses.

A sidewall or roof for a metallurgical furnace is disclosed herein. The sidewall has a cover plate and a hot plate coupled in a spaced apart relation to the cover plate forming an inner volume of the sidewall. The hot plate is configured to contact molten material. A spray cool system is disposed in the interior volume of the sidewall and configured to spray coolant on the hot plate. The hot plate has an inner surface configured to face an interior volume of the metallurgical furnace. The hot plate has an outer surface exposed to the inner volume of the sidewall. A plurality of cooling features extend from the outer surface of the hot plate in a spaced apart relationship. The cooling features are configured to enhance the cooling of the hot plate by the spray cool system.

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.