Method for maintenance of a cooling assembly for a metallurgical furnace

Abstract

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.

Claims

1. A method for maintenance of a cooling assembly for a metallurgical furnace, the cooling assembly comprising: 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, wherein the method includes performing at least one cutting operation with at least one cutting device comprising at least one fixture and a cutting tool that is movably connected to the fixture for a guided movement with respect to the fixture, wherein 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.

2. The method according to claim 1, wherein the cutting tool is connected to the fixture to be movable along a predefined path transversal to an axial direction of the cooling pipe.

3. The method according to claim 1, wherein the fixture is firmly attached to the cooling pipe.

4. The method according to claim 1, further including the step of removing the compensator and installing a new compensator.

5. The method according to claim 4, whereby removing the compensator comprises a first cutting operation of the at least one cutting operation for removing a weld between the compensator and the cooling pipe.

6. The method according to claim 5, whereby the first cutting operation is performed with a first cutting device of the at least one cutting device comprising a first fixture of the at least one fixture and a first cutting tool, which is rotatable with respect to the first fixture.

7. The method according to claim 6, wherein the first cutting tool is adapted to remove the weld.

8. The method according to claim 6, wherein the first fixture is mounted on an inside of the cooling pipe.

9. The method according to claim 5, further including a second cutting operation of the at least one cutting operation for enlarging the shell opening.

10. The method according to claim 9, whereby the second cutting operation is performed with a second cutting device of the at least one cutting device comprising a second fixture of the at least one fixture that is connected to an outside of the cooling pipe, wherein a mount for a second cutting tool is connected to the second fixture for a guided movement with respect to the second fixture and the second cutting tool performs the cutting operation while being held by the mount.

11. The method according to claim 10, wherein the mount is connected for a circular movement.

12. The method according to claim 10, wherein the mount is connected for an eccentric movement with respect to the second fixture.

13. The method according to claim 4, further including the following steps: after removing the compensator, installing a hood, having at least one hood opening of a plurality of hood openings, on the furnace shell so that the hood sealingly covers at least one shell opening, and connecting at least one new compensator of a plurality of new compensators to a hood opening of the hood.

14. The method according to claim 13, wherein the hood has the plurality of hood openings and is installed to cover a plurality of shell openings, and the plurality of new compensators are connected to the plurality of hood openings.

15. The method according to claim 4, wherein the new compensator is installed so that the cooling pipe passes through a sleeve portion of the new compensator, wherein the sleeve portion has an inner cross-section that increases towards the furnace shell.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Preferred embodiments of the disclosure will now be described, by way of example, with reference to the accompanying drawings, in which:

(2) FIG. 1 is a sectional view of a cooling assembly with old compensators;

(3) FIG. 2 is a detail view of a part of the cooling assembly from FIG. 1;

(4) FIG. 3 is a sectional view illustrating a first cutting operation according to the invention;

(5) FIG. 4 is a sectional view illustrating a second cutting operation according to the invention;

(6) FIG. 5 is a view along the direction V in FIG. 4;

(7) FIG. 6 is perspective view of a hood and a plurality of compensators;

(8) FIG. 7 is a perspective view of a plurality of hoods with compensators and cooling pipes; and

(9) FIG. 8 is a detail view of a part of the cooling assembly from FIG. 1 with a new compensator.

DETAILED DESCRIPTION OF THE DRAWINGS

(10) FIG. 1 shows a sectional view of a cooling assembly 1 for a metallurgical furnace, e.g. a blast furnace, before repair. The cooling assembly 1, a detail of which is also shown in the sectional view of FIG. 2, comprises a cooling plate 2 made of copper or a copper alloy. The cooling plate 2, is disposed inside of a furnace shell 20 of the metallurgical furnace. The surface of the cooling plate 2 is shown as plain here, but it could comprise a plurality of ribs and grooves for increasing the surface area. Also, it could be provided with a refractory lining, which is not shown here for sake of simplicity. A plurality of coolant channels 3 are provided in the cooling plate 2.

(11) The cooling assembly 1 also comprises a plurality of cooling pipes 4, each of which has a pipe channel 5 that is connected to a cooling channel 3. The cooling pipe 4 can be made of the same material as the cooling plate 2. Each of the cooling pipes 4 passes through a shell opening 20.1 in the furnace shell 20. The cross-section of the respective shell opening 20.1 is chosen to be larger than the cross-section of the respective cooling pipe 4 to allow for some movement of the cooling pipe 4 with respect to the furnace shell 20. Such movement may in particular result from a thermally induced deformation of the cooling plate 2, to which the cooling pipes 4 are attached. Each cooling pipe 4 extends along an axial direction A that corresponds to a symmetry axis of the respective cooling pipe 4. However, the axial directions A of different cooling pipes 4 are generally not parallel.

(12) A hood 15 may be connected to the furnace shell 20 so that it covers the shell openings 20.1. The hood 15 has a hood opening 15.1 through which a cooling pipe 4 is passed. On an outer side of the hood 15, the cooling pipe 4 is surrounded by a compensator 6, which is welded to the hood 15 so that it is connected to hood opening 15.1. The structure of the compensators 6 can be seen in detail in FIG. 2. It comprises a cylindrical portion 7 that is connected by welding to the hood 15. A bellows 9 is connected to the cylindrical portion 7 by a ring portion 8. An annular sleeve portion 10 is connected on the one hand to the bellows 9 and on the other hand to the outside of the cooling pipe 4. The connection to the cooling pipe 4 is established through an annular first weld 11.

(13) For various reasons, the cooling assembly 1 may need a repair that requires removing the compensators 6 and the hood 15. For this purpose, the first weld 11 connecting the cooling pipe 4 to the compensator sleeve portion 10, a second weld 12 connecting the cylindrical portion 7 to the hood 15 and a third weld 13 connecting the hood 15 to the furnace shell 20 need to be removed. One reason for a repair may be that a compensator 6 or the hood 15 have been damaged. Another reason may be that due to the thermal deformation of the cooling plate 2, one of the cooling pipes 4 has come into contact with a periphery of a shell opening 20.1. In this case, a fix point for the cooling pipe 4 is formed, which hinders movement with respect to the furnace shell 20 and induces mechanical stress that could ultimately lead to a fracture in the cooling pipe 4 itself or in the connection between the cooling pipe 4 and the cooling plate 2. Whether such a direct contact has occurred can be determined for example by endoscopy during a stoppage of the furnace. If such a contact is present, the shell opening 20.1 should be enlarged to remove this issue.

(14) Any of the repair measures coincides with a potential risk of damaging the cooling pipe 4. This risk is minimised or eliminated according to the maintenance method which will be described in the following.

(15) The first weld 11 is removed by a first cutting operation that is illustrated in FIG. 3. For this purpose, special first cutting device 30 is employed.

(16) It should be noted that, although FIG. 3 shows the first cutting operation in connection with a new compensator, i.e. a compensator of the new type, as shown in FIG. 8, the first cutting operation is of course also and primarily designed to be used with an old compensator, i.e. a compensator of the old type, as shown in FIG. 2.

(17) The first cutting device 30 comprises a centring chuck 31 that is disposed at an end of a shaft 32. A fastening device 34 is connected to the shaft 32. A cylindrical cutting sleeve 35 is disposed circumferentially around the shaft 32. At an open end of the cutting sleeve 35, an annular cutting head (or milling head) 36 is disposed. The cutting sleeve 35 and thus the cutting head 36 are movably connected to the shaft 32. On the one hand, the cutting sleeve 35 can perform a longitudinal movement L with respect to the shaft 32, on the other hand it can perform a circular or rotational movement R, which is driven by a drive unit 33 disposed at one end of the shaft 32 opposite the centring chuck 31.

(18) The centring chuck 31 is placed inside the cooling pipe 4 and secured in its position by operating the fastening device 34. Thus, the first cutting device 30 is aligned with respect to the cooling pipe 4. Then, the drive unit 33 is turned on so that the cutting head 36 rotates around the cooling pipe 4 and the cutting sleeve 35 is gradually moved towards the sleeve portion 10, whereby the first weld 11 is removed by machining, or more specifically, by milling. Since the position and the movement of the cutting head 36 are guided by the connection established via the centring chuck 31, the first weld 11 can be removed precisely and without the need for an operator to check the position of the cutting head 36 over and over again. The first cutting operation can therefore be performed very time-effectively. Also, since the first weld is removed by machining, there is no risk of damaging the cooling pipe 4 e.g. by flame cutting. When the first weld 11 has been removed in the depicted way, the second weld 12 and the third weld 13 can be removed by flame cutting, since these welds 12, 13 are disposed further away from the cooling pipe 4, so there is minimal risk of damaging the cooling pipe 4.

(19) When the compensators 6 and the hood 15 have been removed, any of the shell openings 20.1 can be enlarged if necessary. This is done by a second cutting operation illustrated in FIG. 4. An annular second fixture 41 of a second cutting device 40 is circumferentially placed around the cooling pipe 4 and secured thereto by means not depicted here. A guide element 42 is connected to the second fixture 41 so that it is eccentrically movable with respect to the second fixture 41. A holder 44 is attached to the guide element 42. Once the second fixture 41 has been secured to the cooling pipe 4, a cutting torch 45 is inserted into the holder 44. The cutting torch 45 is turned on and cuts through the furnace shell 20. By the guiding function provided through the second fixture 41, the guide element 42 and the holder 40, the cutting torch 45 is moved along a circular path P shown in FIG. 5. In other words, the movement of the cutting torch 45 is guided transversal to the axial direction A along the circular path P, which corresponds to a circular or rotational movement R. Optionally, the holder 44 could allow for a movement of the cutting torch 45 along the axial direction A, but normally the cutting torch 45 is fixedly received inside the holder 44. Once the cutting torch 45 has completed its movement along the path P, a portion 20.3 of the furnace shell 20 near the periphery 20.2 of the shell opening 20.1 has been cut out, thereby enlarging the shell opening 20.1.

(20) Afterwards, a new hood 15 and a new compensator 6 can be installed. The dimensions of the new hood 15 of course have to be selected so that the shell opening 20.1 is fully covered, even if it has been enlarged as described above. They can be designed individually for each installation. In this context, there are various possibilities which are illustrated in FIGS. 6 and 7. As shown in FIG. 6, a single hood 15 with four hood openings 15.1 could be combined with four compensators 6. However, smaller hoods 15 can be used and combined with a lower number of compensators. As shown on the left-hand side of FIG. 7, a single hood 15 with two hood openings 15.1 can be combined with two compensators 6. As shown on the right-hand side of FIG. 7, it is also possible to combine one compensator 6 with a single hood 15. The design of the new compensators 6 corresponds to the one shown in FIG. 2. The hood 15 may have different hood designs is to cover all possible repair cases. If a number of pipes are covered with a single hood, erection time for new compensators can be reduced, thereby keeping the shut-down time of the metallurgical furnace to a minimum.

(21) FIG. 8 shows a cooling pipe connection with a new compensator. A hood 15 may be connected to the furnace shell 20 so that it covers the shell openings 20.1. The hood 15 has a hood opening 15.1 through which a cooling pipe 4 is passed. The hood 15 may be covering more than one shell opening 20.1. Such a hood then comprises more than one hood opening 15.1, one for each cooling pipe 4. On an outer side of the hood 15, the cooling pipe 4 is surrounded by a new compensator 6, which is welded to the hood 15 so that it is connected to hood opening 15.1. The structure of the compensators 6 can be seen in detail in FIG. 8. It comprises a cylindrical portion 7 that is connected by welding to the hood 15. A bellows 9 is connected to the cylindrical portion 7 by a ring portion 8. An annular sleeve portion 10 is connected on the one hand to the bellows 9 and on the other hand to the outside of the cooling pipe 4. The connection to the cooling pipe 4 is established through an annular first weld 11.

(22) An important feature of the new compensator 6 is that the sleeve portion 10 has an inner diameter that increases towards the furnace shell 20, i.e. it increases from an outer end 10.1 towards an inner end 10.2. In other words, the inside surface of the sleeve portion 10 is not cylindrical but conical. This allows for different angular orientations of the sleeve portion 10 with respect to the cooling pipe 4, while still minimising the distance between the sleeve portion 10 and the cooling pipe 4 at the outer end 10.1, where the first weld 11 is applied.