Ironmaking

Foundry Products at Corus Process Engineering have the capability to manufacture Tuyeres, Python Copper Staves, Tuyere Coolers, Cooling plates, Cooling boxes and Cigar Coolers.

Tuyeres from Foundry Products are individually designed to meet the specific operational demands of each end user and manufactured as single piece castings using a technique that eliminates thermal barriers between heated and cooling surfaces. Tuyere design options on offer from Foundry Products include flexible body geometry, abrasion resistant nose protection and refractory body protection, all developed and proven with the co-operation of Corus iron makers and Corus research facilities.

Building on a well proven base Tuyere design and construction technique, options highlighted above have helped to extend individual Tuyere life beyond 5 operational years, with average campaign lives of 2 years becoming increasingly common.

The photographs typify some of the design features on offer and serve to demonstrate how the Foundry Products mode of construction can utilise these features to prolong Tuyere campaign life. The used Tuyere shown survived for in excess of 2000 days operational service without failure.

Python^TM copper staves were originally developed in conjunction with Corus Scunthorpe Works, to facilitate the use of copper staves within a furnace shell designed for iron staves, without the need for new shell access. Python^TM staves have since been adapted to integrate with cooling plates, and in a mini version have been successfully applied to combat localised shell hot spots.

Python^TM staves are produced as copper castings containing integral cooling channels. As the manufacturing process is casting based, external and internal stave geometry can be flexed to accommodate site circumstances. Existing services can therefore be re used, saving on both engineering and furnace down time costs.

The mini stave variant of Python^TM, was designed to fit between existing cooling plates. All necessary water service and structural support is provided by a central pillar and installation requires a single 110mm diameter shell access hole only

Foundry Products manufacture a diverse and extensive range of general Blast Furnace related water cooling components, supplied either in bulk for major capital works, or as batch spares.

In common with all blast furnace related products, Foundry Products are ideally placed to offer a development role, adapting designs as required to reflect either changing circumstances or address specific issues. The full copper body, steel banded cigar cooler shown actually originates from this very process. At a client request, it was developed from a traditional steel/copper cigar cooler assembly to combat corrosion.