APPLICA TION OF SPRA Y COOLED TECHNOLOGY

TO A BOP SHOP FURNACE HOOD

In 1993, U.S. Steel learned ofan innovative system to cool BOF hoods known as spray cooling.
The method was discovered as plans for replacing the hoods of No. 2 Q-BOP were being
researched. While the application ofspray cooling was not used to replace the hoods of
No.2 Q-BOP, the new method is being tested in the No.1 BOP Shop. The method has been
remarkably successful.

The original hoods of No. 2Q-BOP consisted ofa pressurized system of individual water cooled
plate panels bolted together to form a 14'-0" diameter twelve sided duct. The hoods were
scheduledfor replacement due to excessivedowntimes, high maintenancecost and severe
distortion. Failures in these hoods were caused primarily by thermal fatigue cracking due to the
heavy gauge of the hot face plate and inability of the plate to freely expand, due to the attachment
of flow baffies. Additionally, different rates of expansion between the hot and cold faces caused
distortion that lead to cracking at the edges of the panels and gaps in the joints which affected the
ability of the hoods to handle the waste gases,due to water leaks and air infiltration: After
studying the different available hood systems,a membrane tubular hood system was chosen as the
best solution for the No.2 Q-BOP Shop.

During the process of selecting the design and the supplier of the hoods, U. S.Steel received a
proposal submitted by UCAR@ CARBON COI\lfPAI\""Y, INC., with a design that deviated
~-
completely from conventio~j!Lhifod construction. This system featured the use of water sprays
for the cooling of the hot face. The cooling is achieved by an arrangement of nozzles that
produces a pattern of overlapping sprays ( see attachment A). This creates a high degree of
turbulence at atmospheric pressure which promotes the transfer of heat more efficiently than the
conventional flood cooling methods at high pressure. Because spray cooling is an atmospheric
pressure process, it is inherently safer in the event of damage to the hot face plate. The absence
of pressure on the back side of the hot face makes this hood safer by minimizing water leakage.
This also reduces the urgency for shutting down the equipment for repairs. The single piece
construction eliminates the need of expensive spare panels and the simplified piping design and
lower water pressure reduces downtime.

UCAR@ claimed that the application of spray cooling conduced to

In addition, several other benefits not available with conventional pressurized systems made
spray-cooling an ideal application for the BOF hoods. Some of these benefits are:
a. Thinner plate for hot face reduces the magnitude of thermal stresses.
b. Elimination of flow baffies allows the hot face to expand and contract freely.
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BOP Shop
Furnace Hood
4/9/97

c Elimination of flow baffles makes the inner plate independent of the outer plate,
minimizing distortion and failures due to resultant stresses.
d Ability to size and locate spray nozzles according to cooling requirements as it varies
throughout the hood conduces to better water management and efficient utilization of
water .
eo Simple cylindrical shape makes fabrication more economical.
f. Smooth and continuous inside surface avoids the accumulation of slag.
9 Lighter weight reduces supporting system requirements.
h. Water treatment is not required.

The plan presented by UCAR@ was attractive, although its practical use could not be proven as
there were no BOP Shops using this concept anywhere, and consequently the design could not be
considered for the replacement of the hoods in No.2 Q-BOP. However, theoretically the idea
was workable and the possible benefits attractive enough to justify the investment in a test that
would provide enough information to consider the spray cooled design as a possible replacement
for future hoods at the No.1 BOP Shop.

u. S. Steel authorized the test in March 1993, providing that the test would not interfere with
production. The test area was chosen on the following criteria:
I. T est area should be large enough to represent performance of the entire hood.
2. Test area should be subject to the worst conditions (i.e. highest temperature).
3. Test area should provide for easy installation without major modifications.
4. Test area should be easily replaced in case of failure.
Based on the above four characteristics, the removable section of the hood meets all the
requirements.

The UCAR@ spray cooled removable section was designed and built for "M" Furnace at
No.1 BOP Shop (see attachment B). The "M" Furnace is a top blown 250 ton heat furnace
operating with an oxygen blowing rate of 22000 cfm. The spray cooled unit was installed in
September 1993. As of April 8, 1997 the hood has been through 17,960 heats without signs of
failure and minimal maintenance.

The UCAR@ hood receives 2100 gallons of cooling water per minute. The temperature rise of
the cooling water is 50°F. Water is supplied directly from Lake Michigan and requires only
straining to remove particles large enough to plug the nozzles. Chemical treatment is not
required. The cooling water flow rate was determined based on the desire to keep the discharge
water temperature below 150°F. The primary purpose being to prevent scale formation and
minimizing corrosion. The design of the hood permits examination of the water side of the hot
face at any time. This allows for early recognition of cooling related effects taking place. To
date, the spray surface of the hood is clean with some signs of corrosion.
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BOP Shop
Furnace Hood
4/9/97

Instrumentation consists of an orifice type flow measurement device and supply pressure sensor to
monitor cooling water flow. On the discharge side, a temperature sensor is installed to indicate if
an abnormally high temperature condition exists. Flow, supply pressure and discharge
temperature are all monitored by the PLC of the furnace. To prevent damage to the removable
section resulting from a low or no-flow cooling water occurrence, an interlock feature exists in
the lance oxygen supply that will shut off oxygen in the event of a low cooling water flow
condition.

The maintenancework done in this hood has been minimal, after three and a half years of
operation, the repairs consisted of welding four small cracks of about one inch in length that
appeared after about 1,500 heats, replacement ofworn nozzles and welding patches over eroded
spots after 15,000 heats (see attachment C). The cracks were discovered after the first nine
months of operation during detailed inspection of the hood, while the furnace was down for
normal maintenance of the entire hood and were detected by small wet areas in the proximity of
the lower flange. The cracks originated in welded joints and were probably causedby improper
cooling as a consequenceof accumulation of slag inside the spray chamber. Slag falling from the
lance entered the spray chamber when a hatch in the proximity of the lance door was left open for
several days while the furnace was operating.

The accumulation of slag in the lower end of the hood plugged up the drain, reduced the cooling
of the hot face in the proximity of the lower flange and caused slight distortion of the plate. The
abnormal condition was discovered when water exited the overflow pipe of the hood as an
indication of drain problems.

The eroded areas appeared at about 15,000 heats and are the results of abrasive action of the
particulate carried by the waste gases.

The replacement of worn nozzles was done at about 2,300 heats as the result of wear caused by
silt carried by the cooling water. The original design provided brass full cone jet nozzles. A test
using stainless steel nozzles was conducted to determine if the erosion could be minimized by the
use of harder material. After several months of operation, the stainless steel nozzles showed
similar wear pattern. UC.J\R@ and the nozzle manufacturer concluded that the full cone jet
nozzles internal configuration entrap particles of silt in the swirling action of the nozzles and
causes the wear experienced on the brass and stainless steel nozzles, and they recommended the
replacement of the originally installed full cone jet nozzles with spiral jet nozzles. The spiral jet
nozzles distributes water by a different means than the full cone jet. There is no swirling action,
nor is there a location where a particle could get trapped.

The use of the spiral jet nozzles however, did not solve the problem. Frequent inspections
revealed a different wear effect in the nozzles and a distorted spray pattern that was effecting the
water side of the hot face, promoting severe corrosion in some areas due to improper cooling,
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BOP Shop
Furnace Hood
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The spiral nozzles were removed and the original full cone nozzles were installed back in place.
The solution of the nozzle wear problem was found when small holes were drilled in a few nozzles
in the proximity where the wear took place, to provide an escape route to the swirling particles
and stop the erosion.

In the summer of 1996 during the No.1 BOP Shop PM10 Project, two more spray cooled
removable hood sections were installed on the other two furnaces in the #1 BOP Shop, "E" and
"0" furnaces. Both new removable sections are perfonning as designed.

Overall, the general appearanceof all three hoods is excellent. None of the hoods have shown
the typical symptoms of thermal fatigue cracking. The surfacesexposed to heat have not shown
signs of severe wear or distortion and the accumulation of slag is eliminated due to the sniooth
continuous surface of the hood.
 B

UCAR: Spray-Cooled Removable Hood Section for 225 tonne.t?:fJfrff1n) BOF.