SYSTEMS SPRAY-COOLED
Systems Spray-Cooled Incorporated provides Spray-Cooled™ furnace components that operate at atmospheric pressure providing a safer and more efficient system than conventional flood cooling systems. Systems Spray-Cooled™ equipment can be custom designed for individual applications.
Our services include the engineering, design, and supply of non-pressurized water cooled systems for electric steel making furnaces in particular and the entire metals industry in general. The non-pressurized water-cooled systems are based on a unique, patented technology, which has a well-proven track record and offers the following key advantages:
Increased Safety
Systems Spray-Cooled™ equipment is inherently safer because it operates at atmospheric pressure. With a cooling water flow of 122 liters/minute/square meter (3 gallons/minute/square foot) at atmospheric pressure, the small amount of water escaping through a 13 square centimeter (2 square inch) hole, for example, would quickly vaporize.
In contrast, a typical flood-cooled system operating at a pressure of 4.1 bars (60 psi) would force over 60.5 cubic meters/hour (16,000 gal/hour) through the same 13 square centimeter hole.
Improved Environmental Conditions
The one-piece construction of Systems Spray-Cooled™ equipment eliminates individual panel joints. Flame leakage and air infiltration are reduced, improving gas handling efficiency and environmental conditions. And, since the outer surface of the system is also cooler than conventional systems, working conditions within the shop are also improved.
Decreased Downtime
Numerous features of Systems Spray-Cooled™ equipment combine to minimize downtime. The independent inner shell is less susceptible to stress cracking and distortion. The number of valves and interconnecting hoses, along with the leaks that frequently originate from them, have been greatly reduced. Stainless steel components and the scrubbing action of the sprays virtually eliminate scale build-up as well as the need for extensive cooling water treatment.
Because Systems Spray-Cooled™ equipment operates at atmospheric pressure, leaks can be repaired by means of easy "weld-a-patch" techniques without shutting the system down. Plate construction enables repairs to be made from the outside, rather than the inside. This added flexibility means repairs can now be scheduled around production needs. And maintenance personnel can do the work under safer conditions.
Simplified piping design and low water pressure markedly reduce the chance of a breakdown. Minimal maintenance requirements permit the furnace to perform at peak efficiency for longer periods.
Lowered Maintenance Costs
The simplified design made possible by spray cooling minimizes the maintenance required for Systems Spray-Cooled™ equipment. Multiple access ports eliminate the need to remove the system for inspection and preventive maintenance. The inner shell can be examined from the outside and the entire cooling system is easily accessible. Cam-lock "quick disconnects" allow the rapid removal, inspection and reinstallation of each spray bar.
Simplicity of design reduces the weight - the entire system is much lighter than a conventional pressurized configuration. The lighter components are easier to install and reduce support structure requirements. For components that are raised and lowered or moved aside, the lighter weight means easier handling and reduced wear on moving parts.
The smooth inner surface of a Spray-Cooled™ hood reduces the build-up of the molten steel and slag. Skull formation and hazards due to falling slag are minimized.
Systems engineers have made extensive use of CAD/CAM technology in the development of our Spray-Cooled™ equipment to ensure optimum performance. This CAD/CAM data enables us to customize our systems to efficiently fit your specific needs.
Reduced Spare Parts Inventory
Readily available materials and stainless steel components are used in the construction of Spray-Cooled™ equipment. This eliminates the need to inventory spare panels and numerous hoses, valves and fittings.
Extended Service Life
The advanced design features of Systems Spray-Cooled™ equipment result in a long life. Our experience indicates a life of 10,000 heats with minimal maintenance.
Enhances Furnace Efficiency
A Systems Spray-Cooled™ furnace roof exhibits excellent slag retention characteristics, thereby improving the heat retention and the efficiency of the furnace. Experience indicates less than a 1 percent energy increase when compared to refractory roofs.
Spray-Cooled™ sidewalls increase furnace volume. Because they eliminate conventional inside panels, the inner diameter of the furnace is larger resulting in increased scrap volume.
Custom Designed to Your Application
Whatever your cooling needs, our engineers will custom design and manufacture Systems Spray-Cooled™ equipment to fit your unique requirements.
By the very nature of their design, our Spray-Cooled™ equipment can be easily configured to fit any variety of applications.
We have already designed and installed customized Spray-Cooled™ arc furnace roofs, ladle furnace roofs, deltas, sidewalls, ducts, D.E.S. Elbows, AOD and BOF Hoods.
Confirmed by progressive steelmakers since 1987, our customized systems provide greater safety, reduced downtime, lower maintenance costs and improved productivity.
