Serving the Mining / Ore Smelting Industry

Mining / Ore SmeltingGabriel Reyes2024-05-21T13:01:03-05:00

Mining / Ore Smelting Industry

Operational reliability in helping to achieve long-term closed campaigns on the large diameter, submerged arc furnaces of the ore smelting industry have made Systems Spray-Cooled technology the Leader in the field of water-cooled furnace roofs, chimneys, and off-gas duct.

The additional SAFETY and Environmental Benefits provided by our Spray-Cooled™ technology combined with the enhanced slag retention system, natural scrubbing action of the efficient cooling methods, the maintainability from outside, and the inherent monitoring-friendly designs have led to the development and successful implementation of the following iron ore smelting applications:

Free Standing, Panelized Smelter Furnace Roofs
AC Furnaces
DC Furnaces
Steep Cone EAF Roofs (High Profile)
Shallow Cone EAF Roofs (Low Profile)
Chimneys
Off-Gas Stacks
Off-Gas Duct
Paddy Elbows

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EAF Steep Cone Roof Video

Improving smelter furnace reliability while decreasing and easing maintenance requirements, providing safer working conditions in a cleaner environment, reducing the cost of spare parts inventories while extending the service life of the ore smelting equipment, and providing for more production with less energy – Systems Spray-Cooled equipment is “Staying Cool in a Hot Business”.

Spray-Cooled™ Capabilities Brochure

Overview of Systems Spray-Cooled, our division that supplies furnace water-cooling systems for melt shops and steel mills, primarily electric arc furnaces. Learn how Spray-Cooled™ technology decreases furnace maintenance costs while increasing reliability.

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Cool Facts

Cool Fact #1: Spray-Cooled™ Equipment is Safer

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Operating at atmospheric pressure, SYSTEMS Spray-Cooled™ equipment minimizes the amount of water present during an upset event. Our patented technology eliminates the potential of high pressure, high volume water leaks… Just one less thing to worry about!

Spray-Cooled™ Equipment
is SAFER

Cool Fact #2: Spray-Cooled™ More Uptime, Less Downtime

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SYSTEMS Spray-Cooled™ equipment's lack of valves and hoses eliminates two sources for water leaks. Stainless steel components and the inherent scrubbing action of the spray cooling water virtually do away with scale build-up. And, because the system operates at atmospheric pressure, leaks can be repaired on-line, quickly and easily using our quick and easy welded patch.

Spray-Cooled™ MORE UPTIME, LESS DOWNTIME

Cool Fact #3: Spray-Cooled™ Lowers Maintenance Costs

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SYSTEMS Spray-Cooled™ equipment’s custom sized and located, multiple access ports provide free access to the spraying system and wet side hotface. This accessibility eliminates the need to work overhead, and the need to remove equipment off-line for routine inspections and repairs. Thin plate construction drastically reduces spare parts inventories and facilitates a long range, Re-build versus Replace cost reducing campaign.

Spray-Cooled™ LOWERS MAINTENANCE COSTS

Cool Fact #4: Enhances Furnace Efficiency

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Utilizing our patented methods and products, SYSTEMS Spray-Cooled™ equipment exhibits excellent slag retention characteristics - even in extreme heat load areas. Acting as an available “free” insulator, the uniform slag coating improves energy and heat retention inside the furnace. Also, when fully outfitted with Spray-Cooled™ furnace components, additional scrap volume is available without modifications to the furnace superstructure or bottom shell, further reducing energy losses and costly shop logistics.

Spray-Cooled™ ENHANCES FURNACE EFFICIENCY

Cool Fact #5: Facilitates Operational Flexibility

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SYSTEMS Spray-Cooled™ equipment is easily modified to meet the changing needs of a modern steel shop, such as the addition, removal, relocation, or modification of burners, slag tunnels, charge holes, inspection ports, process openings etc. without the need for costly new panels.

Spray-Cooled™ FACILITATES OPERATIONAL FLEXIBILITY

Cool Fact #6: Spray-Cooled™ provides for a Cleaner Environment

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SYSTEMS Spray-Cooled™ equipment’s One-Piece design minimizes flame and fume emissions. This also reduces air infiltration and improves gas handling efficiency. This makes your shop and operating environment cleaner.

Spray-Cooled™ provides for a CLEANER ENVIRONMENT

Cool Fact #7: Spray-Cooled - The Safer Water-Cooled Alternative

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Utilizing our patent protected technology, SYSTEMS Spray-Cooled™ equipment provides a more efficient use of available cooling water to protect your equipment in the most extreme heat load applications in a non-pressurized, gravity return system, thus eliminating the potential of high pressure, high volume water leaks.

Spray-Cooled™ - The Safer Water-Cooled Alternative

Cool Fact #8: Spray-Cooled™ Equipment Eliminates Panel-to-Panel Gaps

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Our one-piece construction means that SYSTEMS Spray-Cooled™ equipment has no panel gaps to allow air infiltration or exfiltration. Not only does this increase overall furnace efficiency but also helps to keep your workplace cleaner.

Spray-Cooled™ Equipment Eliminates Panel-to-Panel Gaps

Cool Fact #9: Spray-Cooled™ Equipment - Rebuild Versus Replace

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By nature of its design and construction, Spray-Cooled™ equipment has an indefinite life. The readily available carbon steel hot face is the only “wear” item in its construction. Upon reaching the cyclic life of the hot face, it is not necessary to replace the entire piece of equipment but simply rebuild the wear item and the Spray-Cooled™ component is as good as new.

Spray-Cooled™ Equipment REBUILD Versus REPLACE

Cool Fact #10: Spray-Cooled™ Equipment Maximum Workability

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Using thin wall, carbon steel plate for construction of SYSTEMS Spray-Cooled™ equipment structural, containment, and hot face elements provides for maximum on-site workability. Combined with the inherent atmospheric cooling system pressure, the thin wall construction facilitates quick “on-the-fly” repairs made from the cooled side for added Safety Precautions.

Spray-Cooled™ Equipment MAXIMUM WORKABILITY