CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority of U.S. Provisional Patent

Application No. 62/769,385, filed November 19, 2018, which is hereby incorporated by reference in its entirety.

FIELD OF INVENTION

[0002] Aspects of the present disclosure relate generally to metallurgical furnaces, and more particularly, to a cooling element for a slag door of a metallurgical furnace, such as an electric arc furnace. Certain embodiments of the technology discussed below can enable and provide efficient cooling to protect a lining of a slag door, while avoiding expense or unavailability of graphite electrodes, and improving safety by avoiding or reducing use of water in an area of the slag pot.

BACKGROUND OF THE INVENTION

[0003] One type of metallurgical furnace is an electric arc furnace (EAF). An EAF is a furnace that heats charged material by means of an electric arc. Industrial arc furnaces range in size from small units of approximately one ton capacity (used in foundries for producing cast iron products) up to about 400 ton units used for secondary steelmaking. Arc furnaces used in research laboratories and by dentists may have a capacity of only a few dozen grams. Industrial electric arc furnace temperatures can be up to 1,800 °C (3,272 °F), while laboratory units can exceed 3,000 °C (5,432 °F). Arc furnaces differ from induction furnaces in that the charge material is directly exposed to an electric arc and the current in the furnace terminals passes through the charged material.

[0004] Referring to FIG. 1, EAF 100 has a refractory-lined vessel 102, usually water- cooled in larger sizes, covered with a retractable roof 104, and through which one or more graphite electrodes 106 enter the furnace 100. The furnace 100 is primarily split into three sections. For example, a shell provides sidewalls and a lower steel bowl, a hearth provides the refractory that lines the lower bowl, and the roof 104 may be refractory -lined or water-cooled, and can be shaped as a section of a sphere or as a frustum (conical section). The roof 104 also supports the refractory delta in its center, through which the one or more graphite electrodes 106 enter.

[0005] AC furnaces usually exhibit a pattern of hot and cold-spots around the hearth perimeter, with the cold-spots located between the electrodes. Modern furnaces mount oxygen- fuel burners in the sidewall and use them to provide chemical energy to the cold-spots, making the heating of the steel more uniform. Additional chemical energy is provided by injecting oxygen and carbon into the furnace; historically this was done through lances (hollow mild- steel tubes) in the slag door, now, this is mainly done through wall-mounted injection units 116 that combine the oxygen-fuel burners and the oxygen or carbon injection systems into one unit.

[0006] In operation, a scrap basket is taken to a melt shop, the roof 104 is swung off the furnace, and the furnace 100 is charged with scrap from the basket. After charging, the roof 104 is swung back over the furnace 100 and meltdown commences. The electrodes 106 are lowered onto the scrap, an arc is struck and the electrodes 106 are then set to bore into the layer of shred at the top of the furnace. Lower voltages are selected for this first part of the operation to protect the roof 104 and walls from excessive heat and damage from the arcs. Once the electrodes 106 have reached the heavy melt at the base of the furnace and the arcs are shielded by the scrap, the voltage can be increased and the electrodes 106 raised slightly, lengthening the arcs and increasing power to the melt. This enables a molten pool to form more rapidly, reducing tap-to-tap times. Oxygen is blown into the scrap, combusting or cutting the steel, and extra chemical heat is provided by wall-mounted oxygen-fuel burners. Both processes accelerate scrap meltdown. Supersonic nozzles enable oxygen jets to penetrate foaming slag and reach the liquid bath.

[0007] An important part of steelmaking is the formation of slag, which floats on the surface of the molten steel. Slag usually consists of metal oxides and acts, as a destination for oxidized impurities, as a thermal blanket (stopping excessive heat loss) and helping to reduce erosion of the refractory lining. For a furnace with basic refractories, which includes most carbon steel -producing furnaces, the usual slag formers are calcium oxide (CaO, in the form of burnt lime) and magnesium oxide (MgO, in the form of dolomite and magnesite). These slag formers are either charged with the scrap, or blown into the furnace during meltdown. Another major component of EAF slag is iron oxide from steel combusting with the injected oxygen. Subsequently, carbon (in the form of coke or coal) is injected into this slag layer, reacting with the iron oxide to form metallic iron and carbon monoxide gas, which then causes the slag to foam, allowing greater thermal efficiency, and better arc stability and electrical efficiency. The slag blanket also covers the arcs, preventing damage to the furnace roof 104 and sidewalls from radiant heat.

[0008] Once the scrap has completely melted down and a flat bath is reached, another bucket of scrap can be charged into the furnace and melted down, although EAF development is moving towards single-charge designs. After the second charge is completely melted, refining operations take place to check and correct the steel chemistry and superheat the melt above its freezing temperature in preparation for tapping. More slag formers are introduced and more oxygen is blown into the bath, burning out impurities such as silicon, sulfur, phosphorus, aluminum, manganese, and calcium, and removing their oxides to the slag. Removal of carbon takes place after these elements have burnt out first, as they have a greater affinity for oxygen. Metals that have a poorer affinity for oxygen than iron, such as nickel and copper, cannot be removed through oxidation and must be controlled through scrap chemistry alone, such as introducing direct reduced iron and pig iron. A foaming slag is maintained throughout, and often overflows the furnace to pour out of slag door 108 into slag pot 110. Temperature sampling and chemical sampling take place via automatic lances. Oxygen and carbon can be automatically measured via special probes that dip into the steel, but for all other elements, a“chill” sample - a small, solidified sample of the steel - is analyzed on an arc- emission spectrometer.

[0009] Once the temperature and chemistry are correct, the steel is tapped out into a preheated ladle through tilting the furnace. For plain-carbon steel furnaces, as soon as slag is detected during tapping, the furnace is rapidly tilted back towards the deslagging side, minimizing slag carryover into a ladle through vertical taphole 112. For some special steel grades, including stainless steel, the slag is poured into the ladle as well, to be treated at the ladle furnace to recover valuable alloying elements. During tapping, some alloy additions are introduced into the metal stream, and more lime is added on top of the ladle to begin building a new slag layer. Often, a few tons of liquid steel and slag is left in the furnace in order to form a“hot heel,” which helps preheat the next charge of scrap and accelerate its meltdown.

[0010] During and after tapping, the furnace 100 is“turned around.” In this process, the slag door 108 is cleaned of solidified slag, the visible refractories are inspected and water- cooled components checked for leaks, and electrodes 106 are inspected for damage or lengthened through the addition of new segments. The taphole 112 is also filled with sand at the completion of tapping. For a 90-ton, medium-power furnace, the whole process will usually take about 60-70 minutes from the tapping of one heat to the tapping of the next (the tap-to- tap time).

[0011] The furnace is completely emptied of steel and slag on a regular basis so that an inspection of the refractories can be made and larger repairs made if necessary. As the refractories are often made from calcined carbonates, they are extremely susceptible to hydration from water, so any suspected leaks from water-cooled components are treated extremely seriously, beyond the immediate concern of potential steam explosions. Excessive refractory wear can lead to breakouts, where the liquid metal and slag penetrate the refractory and furnace shell and escape into the surrounding areas.

[0012] Historically, the slag door 108 is equipped with an electrode 114 made of graphite. This graphite electrode 114 is used to control the slag stream flow and protect the furnace door 108 lining from the aggressive slag. This graphite electrode 114 is a consumable piece that is changed with the furnace shell change periodically. Price of the graphite electrode, however, has increased dramatically, and the graphite electrode is expected to become less available and more expensive in the future. Accordingly, a replacement is needed for the graphite electrode 114.

[0013] Certain embodiments of the technology discussed below can enable and provide efficient cooling to protect a lining of a slag door, while avoiding expense or unavailability of graphite electrodes, and improving safety by avoiding or reducing use of water in an area of the slag pot. Use of water in the zone of the slag pot increases risk of a steam explosion. Accordingly, reducing or avoiding use of water near the slag pot is advantageous over a water cooled system.

[0014] In aspects of the invention, a method of operation for a slag door component cooling system includes coupling a cooling element with a component of a slag door of a metallurgical furnace. The method additionally includes generating a flow of at least one of gas or mist, and directing the flow through a cavity of the cooling element.

[0015] In aspects of the invention, a slag door component cooling apparatus includes means for coupling a cooling element with a component of a slag door of a metallurgical furnace. The apparatus additionally includes means for generating a flow of at least one of gas or mist, and means for directing the flow through a cavity of the cooling element.

[0016] In aspects of the invention, a slag door component cooling system includes a cooling element coupled with a component of a slag door of a metallurgical furnace. The system additionally includes one or more sources generating a flow of at least one of gas or mist, and a pre-exhaust and post-exhaust system directing the flow through a cavity of the cooling element.

[0017] The following includes definitions of various terms and phrases used throughout this specification.

[0018] The terms “about” or“approximately” are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment the terms are defined to be within 10%, preferably, within 5%, more preferably, within 1%, and most preferably, within 0.5%.

[0019] The term“substantially” and its variations are defined to include ranges within

10%, within 5%, within 1%, or within 0.5%.

[0020] The terms“inhibiting” or“reducing” or“preventing” or“avoiding” or any variation of these terms, when used in the claims and/or the specification, includes any measurable decrease or complete inhibition to achieve a desired result.

[0021] The term“effective,” as that term is used in the specification and/or claims, means adequate to accomplish a desired, expected, or intended result.

[0022] The use of the words“a” or“an” when used in conjunction with the term

“comprising,”“including,”“containing,” or“having” in the claims or the specification may mean“one,” but it is also consistent with the meaning of“one or more,”“at least one,” and “one or more than one.”

[0023] The words“comprising” (and any form of comprising, such as“comprise” and

“comprises”),“having” (and any form of having, such as“have” and“has”),“including” (and any form of including, such as“includes” and“include”) or“containing” (and any form of containing, such as“contains” and“contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps. [0024] The process of the present invention can“comprise,”“consist essentially of,” or“consist of’ particular ingredients, components, compositions, etc., disclosed throughout the specification.

[0025] Other objects, features and advantages of the present invention will become apparent from the following figures, detailed description, and examples. It should be understood, however, that the figures, detailed description, and examples, while indicating specific embodiments of the invention, are given by way of illustration only and are not meant to be limiting. Additionally, it is contemplated that changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiments. In further embodiments, additional features may be added to the specific embodiments described herein.

BRIEF DESCRIPTION OF THE DRAWINGS [0026] For a more complete understanding, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

[0027] FIG. l is a block diagram illustrating a metallurgical furnace according to one or more aspects of the present disclosure;

[0028] FIG. 2 is a block diagram illustrating a slag door cooling element configured as a copper and/or copper alloy cylinder having a cavity for flow of air and/or mist according to one or more aspects of the present disclosure;

[0029] FIG. 3 is a block diagram illustrating a slag door component cooling system according to one or more aspects of the present disclosure;

[0030] FIG. 4 is a block diagram illustrating a slag door component cooling system according to one or more aspects of the present disclosure;

[0031] FIG. 5 is a block diagram illustrating a slag door component cooling system according to one or more aspects of the present disclosure; [0032] FIG. 6 is a block diagram illustrating a slag door component cooling system according to one or more aspects of the present disclosure;

[0033] FIG. 7 is a block diagram illustrating example blocks of a method of operation for a slag door component cooling system according to one or more aspects of the present disclosure; and

[0034] FIG. 8 is a block diagram illustrating example blocks of a method of operation for a slag door component cooling system according to one or more aspects of the present disclosure.

DFTATFFD DESCRIPTION OF TTTF INVENTION

[0035] Referring to FIG. 2, a slag door cooling element 200 may be configured as a copper and/or copper alloy cylinder having a cavity 202 for flow of air and/or mist. An inlet 204 is provided for introduction of gas/nitrogen and/or mist into the cavity 202, and an outlet 206 accommodates removal of heated gas/nitrogen and/or mist from cavity 204. The slag door cooling element 200 may be sized and shaped similarly to the graphite electrode 114 ( see FIG. 1) to allow it to be coupled to the same slag door component as the graphite electrode 114 without significant modification of the furnace 100. Alternatively, it is envisioned that the cooling element 200 may have a polygonal shape, or have a combination of flat and curved surfaces. The cooling element 200 does not function as an electrode. Accordingly, replacing the graphite electrode with the cooling element 200 may result in an electrodeless slag door.

[0036] Turning to FIG. 3, it is envisioned that a slag door component cooling system

300 may direct a combination of air and mist through the cavity of the cooling element 200. For example, the cooling element 200 may be coupled with a component of the slag door 108 of the furnace 100. The component may be, for example, a bottom of a door frame or bottom of an opening provided by the slag door 108. A means for coupling the cooling element 200 to the slag door component may be straps, bands, or any coupling mechanism already provided to furnace 100 for holding a graphite electrode. Accordingly, the cooling element 200 may be configured to be held by a same holder edge as has been used to hold the graphite electrode, without major modification. It is envisioned that different sizes and shapes of cooling elements 200 may be used and configured for different types and sizes of furnaces. A refrigerated coolant source 302 may serve as a source of liquid coolant, such as water having a temperature controlled to be in a range of 30 to 40 °C. A liquid pump 304 may be coupled to receive the liquid coolant and force the coolant through a misting nozzle 306 thus injecting mist, such as water droplets, into a passage that also receives a gaseous flow, such as an airflow, from a gaseous flow source 308, such as an air compressor, heat exchanger, and/or nitrogen gas holding tank. A resulting flow of mist bearing gas may thus be directed into and through the cavity of the cooling element 200 through the inlet. An exhaust mechanism, such as a hose or duct, may receive the heated mist bearing gas from the cavity of the cooling element 200 through the outlet, and carry the heated mist bearing gas away from the furnace 100.

[0037] In some embodiments, sensors 310A and 310B, such as temperature, humidity, and/or mass air flow sensors, may be employed in the system 300. For example, one or more sensors 310A may be mounted in a pre-exhaust portion of an exhaust system, such as the passage that provides the mist bearing gas to the inlet of the cooling element. Alternatively or additionally, one or more sensors 310B may be mounted in or proximate to a post-exhaust part of the exhaust system that carries heated gas and/or mist away from the furnace 100. These sensors may provide signals to a controller/processor 312, such as temperature readings, humidity level readings, and/or mass air flow readings. It is envisioned that controller/processor 312 may have memory with instructions that cause controller/processor 312 to trigger an alarm if any of these readings are sufficiently out of range. For example, if flow rate is below a threshold, then an obstruction or breech may be detected. Alternatively or additionally, it is envisioned that controller/processor 312 may be interfaced with the coolant source 302, liquid pump 304, and/or gaseous flow source 308, and that instructions recorded in memory of controller/processor 312 may cause controller/processor 312 to affect control of these devices to maintain a flow rate, humidity level, and/or pre-exhaust and post-exhaust temperatures within predefined, acceptable ranges. For example, temperature of the liquid coolant may be adjusted to adjust temperature of source 302, gaseous flow rate may be adjusted by adjusting one or more valves and/or fan speed of source 308, and humidity may be adjusted by adjusting one or more valves and/or pump speed of pump 304. Controller/processor 312 may also receive readings or signals from source 302, pump 304, and source 308 that indicate current setpoints and/or sensor data, such as temperature of the fluid at source 302 and/or temperature at an air intake of source 308.

[0038] The use of a flow of mist bearing gas in a vicinity of the slag pot avoids or reduces use of water in the vicinity of the slag pot. For example, a fluid facing surface of the misting nozzle 306 may be disposed at least a distance D1 from the slag pot, where distance D1 is at least four meters and preferably greater than five meters Similarly, fluid of source 302 and pump 304 are also disposed at least the distance D1 from the slag pot for improved safety. As a result, the risk of a steam explosion is reduced or avoided compared to a water cooled system.

[0039] Turning now to FIG. 4, it is also envisioned that a slag door component cooling system 400 may be implemented without a controller/processor. In this case, one or more users may exercise manual control over source 402, pump 404, and source 408. It is envisioned that these components may be otherwise identical to source 302 ( see FIG. 3), pump 304, and source 308, respectively. Likewise, electrodes 106, slag door 108, cooling element 200, misting nozzle 306, and distance D1 may be the same as previously described. In some embodiments, it is envisioned that sensors may be implemented for pre-exhaust and post-exhaust measurements, as described above, but to display readings on an active display or using mechanical gauges. Accordingly, users are informed of operating conditions, which aids the users in making decisions to manually adjust the operation of the system components, and/or manually trigger an alarm.

[0040] Turning now to FIG. 5, another embodiment of a slag door component cooling system 500 may not use mist, but simply direct a gaseous flow of air/nitrogen from source 508 through the cavity of the cooling element 200. It is envisioned that source 508 may be identical to sources 308 ( see FIG. 3) and 408 ( see FIG. 4) as described above. Likewise, electrodes 106, slag door 108, and cooling element 200 may be the same as previously described. By avoiding use of water or mist, there is no risk of a steam explosion, and no need to maintain the distance D1 between the slag pot and other components of system 500.

[0041] In some embodiments, sensors 510A and 510B, such as temperature, humidity, and/or mass air flow sensors, may be employed in the system 500. For example, one or more sensors 510A may be mounted in the passage that provides the gaseous flow to the inlet of the cooling element. Alternatively or additionally, one or more sensors 510B may be mounted in or proximate to the exhaust system. These sensors may provide signals to a controller/processor 512, such as temperature readings, humidity level readings, and/or mass air flow readings. It is envisioned that controller/processor 512 may have memory with instructions that cause controller/processor 512 to trigger an alarm if any of these readings are sufficiently out of range. For example, if flow rate is below a threshold, then an obstruction or breech may be detected. Alternatively or additionally, it is envisioned that controller/processor 512 may be interfaced with the gaseous flow source 508, and that instructions recorded in memory of controller/processor 512 may cause controller/processor 512 to affect control of this source 508 to maintain a flow rate and/or pre-exhaust and post-exhaust temperatures within predefined, acceptable ranges. For example, temperature of the gaseous flow may be adjusted, and gaseous flow rate may be adjusted by adjusting one or more valves and/or fan speed of source 508. Controller/processor 512 may also receive readings or signals from source 508 that indicate current setpoints and/or sensor data, such as temperature at an air intake of source 508.

[0042] Turning now to FIG. 6, it is also envisioned that a slag door component cooling system 600 may be implemented without a controller/processor. In this case, one or more users may exercise manual control over source 608. It is envisioned that source 608 may be otherwise identical to source 308 ( see FIG. 3), source 408 ( see FIG. 4), or source 508 ( see FIG. 5), as detailed above. Likewise, electrodes 106, slag door 108, and cooling element 200 may be the same as previously described. In some embodiments, it is envisioned that sensors may be implemented for pre-exhaust and post-exhaust measurements, as described above, but to inform the users of operating conditions, and aid them in making decisions to manually adjust the operation of the system components, and/or manually trigger an alarm.

[0043] Turning now to FIG. 7, a method of operation for a slag door component cooling system begins at block 700. At block 700, the method includes coupling a cooling element with a component of a slag door of a metallurgical furnace. For example, the cooling element may be sized and shaped to couple with the component of the slag door in the same manner as a graphite electrode. Also, the cooling element may be comprised of copper or copper alloy. Further, the cooling element may be configured as a hollow tube having an inlet and an outlet for gas and/or mist. The method may proceed from block 700 to block 702.

[0044] At block 702, the method includes generating a flow of at least one of gas or mist. For example, a flow of gas, such as nitrogen and/or air, may be generated, for example, by an air compressor or heat exchanger. Alternatively or additionally, pressurized, refrigerated water may be forced through a misting nozzle to produce water droplets. The method may proceed from block 702 to block 704.

[0045] At block 704, the method includes directing the flow through a cavity of the cooling element. For example, passages, such as hoses or ventilation ducts, may be employed as a pre-exhaust and post-exhaust system by connecting the hoses or ducts to inlets and outlets of the cooling element. The passages, such as hoses and/or ventilation ducts, that receive the flow and serve as the pre-exhaust system may be employed as a means for directing the flow through the cavity of the cooling element. Alternatively or additionally, the exhaust system, including the pre-exhaust and post-exhaust system, may be used as the means for directing the gas and/or mist through the cavity of the cooling element. The method may proceed from block 704 to block 706.

[0046] At block 706, the method includes receiving at least one of sensed temperature, humidity, or mass air flow readings from sensors disposed to measure the flow at least one of pre-exhaust or post-exhaust. For example, the readings may be received by a controller/processor. Alternatively or additionally, a user may view the readings on an active display or mechanical gauge. The method may proceed from block 706 to block 708.

[0047] At block 708, the method includes adjusting the flow of at least one of gas or mist in response to a determination that at least one of the sensed temperature, humidity, or mass air flow readings is outside of a predetermined range. For example, the controller/processor may make the determination and increase or decrease temperature, pressure, or flow rate of fluid or gas sources. Alternatively or additionally, the controller/processor may trigger an alarm. As another alternative, a user may make the adjustments and/or trigger an alarm manually. The method may return from block 708 to block 702.

[0048] Turning now to FIG. 8, a method of operation for a slag door component cooling system begins at block 800. At block 800, the method includes coupling a cooling element with a component of a slag door of a metallurgical furnace. For example, the cooling element may be sized and shaped to couple with the component of the slag door in the same manner as a graphite electrode. Also, the cooling element may be comprised of copper or copper alloy. Further, the cooling element may be configured as a hollow tube having an inlet and an outlet for gas and/or mist. The method may proceed from block 800 to block 802.

[0049] At block 802, the method includes generating a flow of at least one of gas or mist. For example, a flow of gas, such as nitrogen and/or air, may be generated, for example, by an air compressor or heat exchanger. Alternatively or additionally, pressurized, refrigerated water may be forced through a misting nozzle to produce water droplets. The method may proceed from block 802 to block 804.

[0050] At block 804, the method includes directing the flow through a cavity of the cooling element. For example, passages, such as hoses or ventilation ducts, may be employed as a pre-exhaust and post-exhaust system by connecting the hoses or ducts to inlets and outlets of the cooling element. This exhaust system may thus receive and direct the gas and/or mist through the cavity of the cooling element.

[0051] Although embodiments of the present invention have been described with reference to blocks of FIGS. 7 and 8, it should be appreciated that operation of the present invention is not limited to the particular blocks and/or the particular order of the blocks illustrated in FIGS. 7 and 8. Accordingly, embodiments of the invention may provide functionality as described herein using various blocks in a sequence different than that of FIGS. 7 and 8.

[0052] Those of skill in the art would understand that information and signals may be represented using any of a variety of different technologies and techniques. For example, data, instructions, commands, information, signals, bits, symbols, and chips that may be referenced throughout the above description may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles, or any combination thereof.

[0053] The functional blocks and modules described herein (e.g., the functional blocks and modules in FIGS. 3-8) may comprise processors, electronics devices, hardware devices, electronics components, logical circuits, memories, software codes, firmware codes, etc., or any combination thereof.

[0054] Those of skill would further appreciate that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the disclosure herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular annlication. but such implementation decisions should not be interpreted as causing a departure from the scope of the present disclosure. Skilled artisans will also readily recognize that the order or combination of components, methods, or interactions that are described herein are merely examples and that the components, methods, or interactions of the various aspects of the present disclosure may be combined or performed in ways other than those illustrated and described herein.

[0055] The various illustrative logical blocks, modules, and circuits described in connection with the disclosure herein may be implemented or performed with a general- purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.

[0056] The steps of a method or algorithm described in connection with the disclosure herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such that the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In the alternative, the processor and the storage medium may reside as discrete components in a user terminal.

[0057] In one or more exemplary designs, the functions described may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium. Computer-readable media includes both computer storage media and communication media including any medium that facilitates transfer of a computer program from one place to another. Computer-readable storage media may be any available media that can be accessed by a general purpose or special purpose computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code means in the form of instructions or data structures and that can be accessed by a general- purpose or special-purpose computer, or a general-purpose or special-purpose processor. Also, a connection may be properly termed a computer-readable medium. For example, if the software is transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, or digital subscriber line (DSL), then the coaxial cable, fiber optic cable, twisted pair, or DSL, are included in the definition of medium. Disk and disc, as used herein, includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), hard disk, solid state disk, and blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media.

[0058] As used herein, including in the claims, the term“and/or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination. Also, as used herein, including in the claims,“or” as used in a list of items prefaced by“at least one of’ indicates a disjunctive list such that, for example, a list of“at least one of A, B, or C” means A or B or C or AB or AC or BC or ABC (i.e., A and B and C) or any of these in any combination thereof.

[0059] In the context of the present invention, at least the following 20 embodiments are disclosed. Embodiment 1 is a method of operation for a slag door component cooling system. The method includes coupling a cooling element with a component of a slag door of a metallurgical furnace. The method further includes generating a flow of at least one of gas or mist and directing the flow through a cavity of the cooling element. Embodiment 2 is the method of embodiment 1, wherein the cooling element contains copper or copper alloy. Embodiment 3 is the method of either of embodiments 1 or 2, wherein the cooling element is configured as a tube. Embodiment 4 is the method of any of embodiments 1 to 3, wherein the gas contains at least one of nitrogen or air. Embodiment 5 is the method of any of embodiments I to 4, wherein the mist contains water droplets. Embodiment 6 is the method of any of embodiments 1 to 5, further including receiving at least one of sensed temperature, humidity, or mass air flow readings from sensors disposed to measure the flow at least one of pre-exhaust or post-exhaust. Embodiment 7 is the method of embodiment 6, further including making a determination that at least one of the sensed temperature, humidity, or mass air flow readings is outside of a predetermined range, and triggering an alarm in response to the determination. Embodiment 8 is the method of embodiment 6, further including making a determination that at least one of the sensed temperature, humidity, or mass air flow readings is outside of a predetermined range, and adjusting the flow of at least one of gas or mist in response to the determination.

[0060] Embodiment 9 is a slag door component cooling apparatus. The apparatus includes means for coupling a cooling element with a component of a slag door of a metallurgical furnace. The method also includes means for generating a flow of at least one of gas or mist. The method further includes means for directing the flow through a cavity of the cooling element. Embodiment 10 is the apparatus of embodiment 9, further including means for receiving at least one of sensed temperature, humidity, or mass air flow readings from sensors disposed to measure the flow at least one of pre-exhaust or post-exhaust. Embodiment

I I is the apparatus of embodiment 10, further including means for making a determination that at least one of the sensed temperature, humidity, or mass air flow readings is outside of a predetermined range, and means for triggering an alarm in response to the determination. Embodiment 12 is the apparatus of embodiment 10, further including means for making a determination that at least one of the sensed temperature, humidity, or mass air flow readings is outside of a predetermined range, and means for adjusting the flow of at least one of gas or mist in response to the determination.

[0061] Embodiment 13 is a slag door component cooling system. The system includes a cooling element coupled with a component of a slag door of a metallurgical furnace. The system further includes one or more sources generating a flow of at least one of gas or mist. The system also includes a pre-exhaust and post-exhaust system directing the flow through a cavity of the cooling element. Embodiment 14 is the system of embodiment 13, wherein the cooling element contains copper or copper alloy. Embodiment 15 is the system of either of embodiments 13 or 14, wherein the cooling element is configured as a tube. Embodiment 16 is the system of any of embodiments 13 to 15, wherein the gas contains at least one of nitrogen or air. Embodiment 17 is the system of any of embodiments 13 to 15, wherein the mist contains water droplets. Embodiment 18 is the system of any of embodiments 13 to 15, further including at least one processor receiving at least one of sensed temperature, humidity, or mass air flow readings from one or more sensors disposed to measure the flow at least one of pre-exhaust or post-exhaust. Embodiment 19 is the system of embodiment 18, wherein the at least one processor is configured to make a determination that at least one of the sensed temperature, humidity, or mass air flow readings is outside of a predetermined range, and trigger an alarm in response to the determination. Embodiment 20 is the system of embodiment 18, wherein the at least one processor is configured to make a determination that at least one of the sensed temperature, humidity, or mass air flow readings is outside of a predetermined range, and adjust the flow of at least one of gas or mist in response to the determination.

[0062] Although embodiments of the present application and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the embodiments as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the above disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.