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Electric Arc Furnace Water Cooled Cover with Advanced Cooling System

  • Electric Arc Furnace Water Cooled Cover with Advanced Cooling System
  • Electric Arc Furnace Water Cooled Cover with Advanced Cooling System
Place of Origin Shaanxi, China
Brand Name Shaanxi Chengda
Certification ISO9001
Model Number water cooled furnace roof
Minimum Order Quantity 1set
Price The price will be negotiated based on the technical requirements and supply scope of Party A
Packaging Details Discuss according to the specific requirements of Party A
Delivery Time 2 months
Payment Terms L/C,D/A,D/P,T/T,Western Union,MoneyGram
Supply Ability Complete production supply chain, supply on time, and meet quality standards

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Electric Arc Furnace Roof

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Electric Arc Furnace Water Cooled Roof

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Advanced Cooling System Water Cooled Roof
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Product Description

Electric arc furnace water cooled furnace roof



Electric Arc Furnace Water-Cooled Cover

The electric arc furnace (EAF) water-cooled cover is a critical thermal protection and process control component for electric arc furnaces—equipment widely used in steelmaking, ferroalloy refining, and non-ferrous metal smelting. It replaces traditional refractory brick covers with a closed water circulation structure to seal the furnace top, isolate high-temperature arc radiation, and manage furnace gas. This component directly impacts the EAF’s energy efficiency, safety, and environmental performance, making it indispensable for modern high-efficiency EAF operations.

1. Core Functions & Working Principles

Core Functions

Unlike general industrial furnace covers, the EAF water-cooled cover is designed to withstand extreme conditions (high arc temperature, molten splashes, and corrosive furnace gas), with four key functions:
  • High-Temperature Shielding: Resists direct scouring from 1600-2200°C arc radiation and molten steel/slag splashes, preventing deformation or burnout of the EAF’s steel shell and extending the furnace body’s service life.
  • Furnace Gas Sealing & Recovery: For modern closed EAFs (e.g., ultra-high-power EAFs for steelmaking), it forms an airtight space with the furnace body to collect CO-rich furnace gas. This gas is either reused as fuel (reducing energy consumption) or treated to meet emission standards, avoiding toxic gas leakage.
  • Heat Loss Reduction: The water-cooled structure minimizes top heat dissipation—compared to traditional refractory covers, it cuts heat loss by 35%-55%, improving the EAF’s thermal efficiency and reducing electricity consumption (typically by 30-60 kWh/ton of steel).
  • Operational Flexibility: Supports frequent opening/closing (for scrap charging, electrode adjustment, and tapping) while maintaining structural stability, reducing downtime for maintenance or process transitions.

Working Principle

It operates on the principle of continuous heat transfer via cooling water circulation, ensuring the cover remains within a safe temperature range (outer wall ≤80°C) even under extreme furnace conditions:
  1. The cover’s internal structure (hollow panels or embedded coils) is connected to an external closed cooling system (including water pumps, heat exchangers, and expansion tanks).
  2. Low-temperature cooling water (30-40°C, usually softened or demineralized to avoid scaling) is pumped into the cover’s internal channels.
  3. High-temperature heat from the furnace (arc radiation, hot furnace gas) is absorbed by the cover’s inner wall and transferred to the flowing cooling water.
  4. Heated water (50-60°C) flows out of the cover, is cooled by heat exchangers (or cooling towers), and is recycled back to the cover—forming a continuous, energy-efficient heat dissipation cycle.

2. Structural Design & Material Selection

The EAF water-cooled cover features a modular, high-strength design, with materials selected to balance heat resistance, corrosion resistance, and mechanical stability.
Structural Component Function Typical Materials Design Considerations
Cover Body Frame Supports the entire structure, connects to lifting mechanisms Q355B low-alloy steel (high tensile strength, good weldability) or 16Mn steel Thickened to 12-16 mm to withstand mechanical stress during lifting/locking
Water-Cooled Panels/Coils Core heat-absorbing part, forms the cover’s inner/outer layers - Inner layer: 316L stainless steel (resists corrosion from acidic furnace gas, e.g., SO₂)

- Outer layer: Carbon steel (cost-effective, for low-temperature environments)		 Panels: 8-12 mm thick, with 150-200 mm spacing between internal channels to avoid hot spots

Coils: Φ38-57 mm seamless steel pipes (20# steel) for uniform water flow
Electrode Holes & Seals Accommodates graphite electrodes, prevents gas leakage High-temperature graphite packing + stainless steel pressure rings Holes are lined with wear-resistant sleeves (to resist electrode friction) and have adjustable seals for electrode diameter changes
Lifting/Locking Mechanism Enables cover opening/closing, ensures sealing pressure Alloy steel hinges + hydraulic cylinders (or pneumatic actuators) Equipped with position sensors to avoid misalignment; locking force ≥0.1 MPa to ensure airtightness
Water Inlet/Outlet Joints Connects to external cooling system 304 stainless steel quick-connect joints (with O-ring seals for anti-leakage) Designed with check valves to prevent water backflow during shutdown
Thermal Insulation Layer Reduces external heat loss (outer wall) Ceramic fiber blanket (100-150 mm thick, withstands 800°C) Applied to the outer frame to protect lifting components and improve operator safety

3. Key Technical Parameters

Parameters are customized based on the EAF’s capacity (e.g., 50t, 100t, 200t steelmaking EAFs) and process requirements (e.g., ultra-high power, low-carbon steel production). Core parameters include:
Parameter Category Specific Indicators Typical Values for 100t Steelmaking EAF
Cooling Water System Inlet temperature

Outlet temperature

Water pressure

Water flow rate		 ≤40°C

≤60°C

0.5-0.7 MPa

120-150 m³/h
Structural Performance Maximum withstand temperature (inner wall)

Heat dissipation coefficient

Sealing leakage rate		 2200°C

≤120 W/(m²·K)

≤0.05% (furnace gas)
Operational Parameters Lifting speed

Locking pressure

Service life		 0.8-1.2 m/min

0.12-0.15 MPa

3-5 years
Dimensional Parameters Diameter (for circular EAFs)

Weight

Electrode hole diameter		 4.5-5.5 m

8-12 tons

Φ400-600 mm

4. Application Scenarios & Performance Advantages

It is widely used in various EAF types, with tailored designs for different smelting goals:
EAF Application Type Customized Design Features Performance Advantages
Steelmaking EAF (ultra-high power, UHP) Large water flow rate (to handle high arc heat), reinforced electrode seals (for CO recovery) Reduces steelmaking electricity consumption by 40-60 kWh/ton; furnace gas collection rate ≥98%
Ferroalloy Refining EAF (e.g., low-carbon ferrochrome) Corrosion-resistant inner panels (to resist chrome-rich slag), compact structure Extends cover life to 4-5 years; reduces chromium loss during refining by 1-2%
Non-Ferrous Smelting EAF (e.g., copper alloy smelting) Heat-resistant alloy panels (to withstand 2000°C+), easy-to-clean inner surface Prevents alloy contamination from cover material; simplifies maintenance
Compared to traditional refractory brick covers, its advantages are significant:
Performance Metric Water-Cooled Cover Traditional Refractory Cover
Service Life 3-5 years 1-3 months (requires frequent replacement)
Heat Loss 35-55% reduction High (accounting for 20-30% of total heat loss)
Maintenance Frequency 2-3 times/year 1-2 times/month
Furnace Gas Sealing Leakage rate ≤0.05% Poor (leakage rate ≥5%)

5. Daily Maintenance & Fault Handling

To ensure safe and stable operation, strict daily maintenance and timely fault resolution are required:

Daily Maintenance (Per Shift)

  1. Cooling System Check: Monitor water inlet/outlet temperature, pressure, and flow rate. If the outlet temperature exceeds 60°C or pressure drops by ≥0.1 MPa, stop the furnace to inspect for pipe blockage or leakage.
  2. Sealing Inspection: Use a gas detector to check for furnace gas leakage at electrode holes and cover edges. Replace aging graphite packing or gaskets if leakage is detected.
  3. Structural Inspection: Use an infrared thermometer to scan the cover body—local temperatures exceeding 100°C indicate potential pipe blockage or water shortage.
  4. Lifting Mechanism Check: Inspect hydraulic cylinders and hinges for lubrication; ensure position sensors work normally to avoid misalignment.

Common Faults & Solutions

Fault Phenomenon Possible Cause Solution
Local overheating (≥100°C) Water pipe blockage (scaling or slag accumulation) 1. Stop the furnace and flush pipes with 5-8% hydrochloric acid (to remove scale); 2. Replace severely blocked pipes.
Furnace gas leakage at electrode holes Worn graphite packing, loose pressure rings 1. Tighten pressure rings; 2. Replace packing with high-temperature graphite material.
Cooling water pressure drop Pipe rupture (high-temperature fatigue) or joint loosening 1. Isolate the cover from the cooling system; 2. Weld ruptured pipes or replace faulty joints.
Lifting mechanism jamming Hinge wear, insufficient lubrication 1. Clean hinges and apply high-temperature lubricating grease (e.g., molybdenum disulfide); 2. Replace worn parts.


There are many types of furnace cover structures of electric arc furnaces, Can be selected according to the different power of electric arc furnaces.

1.Brick type furnace cover

2. Box type water cooling furnace cover

3. Tube type water cooling furnace cover

4. Atomizing furnace cover
Among them, the brick type furnace cover is suitable for ordinary power arc furnace.
Box type water cooled furnace covers are suitable for high power arc furnaces
The tube type water cooled furnace cover is mainly used in ultra-high power electric arc furnace, and the atomizing furnace cover has a wide application range and is basically not limited by power.
In the design of ultra-high power DC electric arc furnace, the tube type water-cooled furnace cover with good cooling effect and the most widely used is selected.


Water cooling furnace cover structure diagram:


Electric Arc Furnace Water Cooled Cover with Advanced Cooling System 0

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