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UltraLife® Stave and DoubleLocking Refractory System
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Copper Stave Water Pipeand PlugWeld Repair System(Patent Pending):
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CIM-Cooler Backup Coolingfor Damaged Cooling Water Circuits(Patent Pending):
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Wear Monitors
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Blast Furnace Cooling Component Design and Failure Analysis:
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Additional Equipment
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UltraLife® Stave and Double Locking Refractory System
UltraLife® Copper Staves design features:
Proven, reliable design- Imbedded “cast-in” pipe with superior pipe bond
- Flexibility of cooling circuit design
- Double compartment, intertwined circuit designs allowing for closer water pipes, consistent high water velocity, uniform stave temperature and double protection against leakage.
- Adaptation to existing equipment / shell penetrations
- Uniform face profile regardless of irregular shell conditions, uniform flow profile, consistent pressure drop
- Ease of installation
- Staves in service since 2002 without a stave replacement
Patented UltraLife® Copper Casting Technology eliminates the following failure mechanism associated with drilled and plugged staves:
Water pipe welds at back of the stave- Flat faceted furnace profiles
- Plug welds
- Large distances between water channels
- Compensator bellows
UltraLife® Double-Locking Refractory System (Patent Pending):
Eliminates weld cracking, stave defection, exposed ram gaps, protruding edges and stress concentrations that cause isolated loss of refractory and accretions.- Increases vertical brick strength
- Circular expansion, groove lock maintains an intimate bond between stave and refractory
- Eliminates copper stave face abrasion with protective refractory layer
- Allows refractory replacement without removing the stave.
UltraLife® Double-Locking Long Lasting Refractory Materials:
- High quality graphite and SiC refractories for increased life
- Material selections for your specific application
- Interchangeable design for multiple materials
- All materials establish a round profile to your furnace
Copper Stave Water Pipe and Plug Weld Repair System (Patent Pending):
Repair the failures of traditional drilled and plugged stave systems- Quick installation to allow short outage repairs
- Reestablishes water cooling directly to copper surfaces
- Custom designed and tested for your application, on-site support and training
CIM-Cooler Backup Cooling for Damaged Cooling Water Circuits (Patent Pending):
Temporary replacement for cooling water circuits that are damaged or leaking during production- Allows the process to continue until repairs can be made
- Uses atomized water in the cooling gas to allow for optimum cooling
- Nitrogen and air or any pressurized gas with good thermal transfer properties can be used for cooling
- Water flow is typically less than 5 gpm (20 lpm) allowing little to no water being introduced to the process
Wear Monitors
Allows for continuous monitoring of process information- Accurately measures stave and refractory thickness
- Can be installed and read during routine furnace outages
- Can be retrofit to existing stave systems or included in original installation
- Ability to identify if refractory is wearing and can be replaced without removing staves
- Helps to extend furnace campaigns and improve operating methods
Blast Furnace Cooling Component Design and Failure Analysis:
Root cause analysis for cooling component failures- Computational fluid dynamics, thermal and stress analyses for failure validation and replacement design verification
- Assistance in development of operational changes to increase lining life
Additional Equipment Includes:
- Cast Copper Hearth Staves
- Cast Iron Staves
- Copper Plate Coolers
- Cigar Coolers
- Taphole Seal Plates
Additionally, Berry Metal Company provides:
- Post Combustion Lances and Lance Tips
- Camera Lances
- Contact Shoes for LMF & EAF Electrode Holders
- Water-Cooled Fabricated Panels for Sidewall Burners and EBT Burners
- Water-Cooled Fabricated Sand Hole Panel
- Pipe bending and fabrication
- Spare Parts