A coolant for use in support of a pyrometallurgical furnace includes a circulating rich glycol solution. Substantially all the molecules of any initial weight of water it includes have been physically absorbed by a hygroscopic action into an initial weight of a glycol solvent. Substantially all the molecules of the initial weight of water included are suspended in solution between the molecules of a first portion of the initial weight of glycol solvent due to the hygroscopic action. A substantial remaining second portion of the initial weight of glycol solvent stays available to physically absorb any other water or steam that may later come in contact with the rich glycol solution as it circulates inside a desiccation containment vessel.

A coolant for use in support of a pyrometallurgical furnace includes a circulating rich glycol solution. Substantially all the molecules of any initial weight of water it includes have been physically absorbed by a hygroscopic action into an initial weight of a glycol solvent. Substantially all the molecules of the initial weight of water included are suspended in solution between the molecules of a first portion of the initial weight of glycol solvent due to the hygroscopic action. A substantial remaining second portion of the initial weight of glycol solvent stays available to physically absorb any other water or steam that may later come in contact with the rich glycol solution as it circulates inside a desiccation containment vessel.

High heat flux furnace cooler comprise CuNi pipe coils cast inside pours of high purity (99%-Wt) copper. The depth of front copper cover over the pipe coils in the hot face to manufacture into the casting is derived from a projection of the thermal and stress conditions existing at the cooler's end-of-campaign-life. CFD and/or FEA analyses and modeling is used for a trial-and-error zeroing in of the optimum geometries to employ in the original casting of CuNi pipe coils in high purity copper casting. Individual pipe coil positions to cast inside a copper casting mold are secured with devices that will not melt, cause thermal shear stresses, or be the source of contaminations or copper defects. Pipe bonding to the casting results because the differential coefficient of expansions of the pipes' and the casting's copper alloys involved do not exceed the yield strength of the casting copper during operational thermal cycling.

High heat flux furnace cooler comprise CuNi pipe coils cast inside pours of high purity (99%-Wt) copper. The depth of front copper cover over the pipe coils in the hot face to manufacture into the casting is derived from a projection of the thermal and stress conditions existing at the cooler's end-of-campaign-life. CFD and/or FEA analyses and modeling is used for a trial-and-error zeroing in of the optimum geometries to employ in the original casting of CuNi pipe coils in high purity copper casting. Individual pipe coil positions to cast inside a copper casting mold are secured with devices that will not melt, cause thermal shear stresses, or be the source of contaminations or copper defects. Pipe bonding to the casting results because the differential coefficient of expansions of the pipes' and the casting's copper alloys involved do not exceed the yield strength of the casting copper during operational thermal cycling.

A water pipe collection box and stave support for a cast copper stave cooler body panel that has disposed within it a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends clustered together in a single group that exits a backside of the copper stave cooler body panel. A cast copper stave cooler body panel that has disposed within a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends clustered together in a single group that exits a backside of the copper stave cooler body panel. A blast furnace having stave cooler body panels variously profiled to fit inside, and where each has disposed within it a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends are clustered together in a single group that exits a backside of each copper stave cooler body panel.

A water pipe collection box and stave support for a cast copper stave cooler body panel that has disposed within it a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends clustered together in a single group that exits a backside of the copper stave cooler body panel. A cast copper stave cooler body panel that has disposed within a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends clustered together in a single group that exits a backside of the copper stave cooler body panel. A blast furnace having stave cooler body panels variously profiled to fit inside, and where each has disposed within it a circuit of water pipes with a number of loops each with an inlet end and an outlet end, and all such inlet ends and outlet ends are clustered together in a single group that exits a backside of each copper stave cooler body panel.

All of a cast-iron or cast-copper stave cooler's weight is supported inside a furnace containment shell by a single gas-tight steel collar on its backside face. All the coolant piping in each cooler has every external fluid connection collected and routed together through the one steel collar. A wear protection barrier is disposed on the hot face. At least one of horizontal rows of ribs and channels retain metal inserts or refractory bricks, or pockets that assist in the retention of castable cement and/or accretions frozen in place from a melt, or an application of an area of hardfacing that is welded on in bead, crosshatch, or weave pattern.

All of a cast-iron or cast-copper stave cooler's weight is supported inside a furnace containment shell by a single gas-tight steel collar on its backside face. All the coolant piping in each cooler has every external fluid connection collected and routed together through the one steel collar. A wear protection barrier is disposed on the hot face. At least one of horizontal rows of ribs and channels retain metal inserts or refractory bricks, or pockets that assist in the retention of castable cement and/or accretions frozen in place from a melt, or an application of an area of hardfacing that is welded on in bead, crosshatch, or weave pattern.

The present disclosure relates to a method of detecting crack propagation in a wall of a metallurgical furnace by a detection unit. The detection unit is configured to extract one or more dominant frequency parameters from the corresponding reflected stress signal, and analysing, a phase from each dominant frequency parameters. The analysing of the phase comprises determines, one or more coefficients for each dominant frequency parameters. The detection unit then identifies, a dominant phase based on the corresponding one or more coefficients and selects a frequency relevant to a thickness parameter based on the dominant phase. The crack propagation in the wall of the metallurgical furnace is then detected based on the frequency relevant to the thickness parameter at each of the one or more locations. The present disclosure provides an accurate method for determining condition of refractory lining by elimination unwanted noise signals.

All of a cast-iron or cast-copper stave cooler's weight is supported inside a furnace containment shell by single gas-tight steel collar on the backside. All the coolant piping in each cooler has every external connection collected and routed together through the one steel collar. A wear protection barrier is disposed on the hot face. Such is limited to include at least one of horizontal rows of ribs and channels that retain metal inserts or refractory bricks, or pockets that assist in the retention of castable cement and/or accretions frozen in place from a melt, or an application of an area of hardfacing that is welded on in bead, crosshatch, or weave pattern.