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.

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 stave comprising an outer housing, an inner pipe circuit comprising individual pipes housed within the outer housing, wherein the individual pipes each has an inlet end and an outlet end and wherein each pipe may or may not be mechanically connected to another pipe, and a manifold, integral with or disposed on or in the housing; wherein the inlet and/or outlet ends of each individual pipe is disposed in or housed by the manifold. The manifold may be made of carbon steel while the housing may be made of copper. Each of the inlet and outlet ends of each individual pipe may be surrounded in part by cast copper within a housing of the manifold.

A stave comprising an outer housing, an inner pipe circuit comprising individual pipes housed within the outer housing, wherein the individual pipes each has an inlet end and an outlet end and wherein each pipe may or may not be mechanically connected to another pipe, and a manifold, integral with or disposed on or in the housing; wherein the inlet and/or outlet ends of each individual pipe is disposed in or housed by the manifold. The manifold may be made of carbon steel while the housing may be made of copper. Each of the inlet and outlet ends of each individual pipe may be surrounded in part by cast copper within a housing of the manifold.

A stave comprising a housing, an inner cooling fluid circuit comprising a cooling fluid inlet, a cooling fluid outlet and one or more cooling fluid pipes housed within, or cooling fluid passageways defined by, the housing, wherein each cooling fluid pipe and/or passageway is in direct or indirect fluid communication with the cooling fluid inlet and the cooling fluid outlet; and a manifold, integral with or disposed on or in the housing, that provides support for installation of the stave on a furnace shell; wherein the manifold has one or more inlet pipes, or defines one or more inlet passageways, for providing cooling fluid to the cooling fluid inlet of the cooling fluid circuit of the housing; and wherein the manifold has one or more outlet pipes, or defines one or more outlet passageways, for receiving cooling fluid from the cooling fluid outlet of the cooling fluid circuit of the housing.

The campaign lives are extended and the risks of process gas leaks past seals are reduced by improved stave coolers that each hang together inside steel shelled furnaces by a single neck extended out through a steel jacketed collar. All the coolant circuits inside the stave cooler are collected and grouped together to pass inside through the one collar. The steel in the collar is matched to the steel used in the containment shell, and a matching steel weld seals them together. Thermal stresses are thereby prevented from accumulating over separation distances as a consequent of the steel's coefficient of expansion. A single point of penetration has no separation distance to another.

Cast-iron and cast-copper stave coolers improve the campaign lives of furnaces with steel shelled vessels. Each stave cooler has a single rectangular body with one-only protruding neck on its back that includes a steel collar adaptor. All the coolant piping passes in a group through the protruding neck from two or more independent coolant circuits inside the stave body. Such stave coolers are configured to depend entirely for all their vertical mechanical support on a single hanging of the protruding neck as a through-bulkhead in a single corresponding penetration of the containment shell. Thus, a single annular welded steel-to-steel gas seal around the through-bulkhead is all that's needed inside the steel containment shell for each stave cooler. Coolant piping is laid flat in a single common layer, inside to a hot face. Cast-copper stave cooler hot faces include an abrasion resistant layer that extends campaign lives beyond ten years.

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.