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Simulation study on heat transfer behavior of blast furnace cast iron cooling stave after damage.

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Title: Simulation study on heat transfer behavior of blast furnace cast iron cooling stave after damage.
Authors: Zhao, Yuehan1 (AUTHOR) zyuehan1215@163.com, Yan, Bingji1,2 (AUTHOR) bjyan@suda.edu.cn, Wang, Jianfeng2 (AUTHOR) 751224740@qq.com, Luo, Guoping1 (AUTHOR) luoguoping3@126.com, Guo, Hongwei2 (AUTHOR) guohongwei@suda.edu.cn
Source: Chemical Engineering Science. Jun2026, Vol. 327, pN.PAG-N.PAG. 1p.
Subjects: Heat transfer, Stress concentration, Temperature distribution, Erosion, Heat exchanger efficiency, Blast furnaces, Finite element method
Abstract: • Development of a Physical Model for Post-Damaged Cast Iron Cooling staves. • Decline in Cooling Efficiency with Increasing Damage Severity. • Correlation Between Temperature-Stress Distribution and Damage Evolution. As a critical component of the blast furnace cooling system, the life and performance of the cooling stave directly affect the stability and safety of the blast furnace. Among these, cast iron cooling staves have good wear resistance characteristics, due to their weak thermal conductivity, they have lower cooling efficiency. The internal materials and gas flow in the blast furnace, along with thermal shock, can easily cause damage to the cooling stave, further weakening its cooling effect. This paper establishes physical models of cast iron cooling staves in three states: undamaged, cracked, and with exposed water pipes, and compares the impact of different degrees of damage on the temperature and stress field distribution characteristics using finite element analysis methods. The research results show that the initial stage of damage is characterized by wall cracking with the thinning of the dovetail groove the furnace shell temperature rises the temperature difference of cooling water increases the cooling efficiency gradually deteriorates and the stress concentration in the cracks intensifies when developing to the state of exposed water pipes the cooling efficiency drops sharply the area around the exposed water pipes becomes a new stress concentration zone which accelerates wall spalling and water pipe erosion while refractory mud filling can only alleviate thermal shock in the short term it is difficult to completely solve the problems of insufficient cooling efficiency and long-term structural damage and the research conclusions can provide a basis for the design optimization and service life prediction of cast iron cooling staves. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
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Abstract:• Development of a Physical Model for Post-Damaged Cast Iron Cooling staves. • Decline in Cooling Efficiency with Increasing Damage Severity. • Correlation Between Temperature-Stress Distribution and Damage Evolution. As a critical component of the blast furnace cooling system, the life and performance of the cooling stave directly affect the stability and safety of the blast furnace. Among these, cast iron cooling staves have good wear resistance characteristics, due to their weak thermal conductivity, they have lower cooling efficiency. The internal materials and gas flow in the blast furnace, along with thermal shock, can easily cause damage to the cooling stave, further weakening its cooling effect. This paper establishes physical models of cast iron cooling staves in three states: undamaged, cracked, and with exposed water pipes, and compares the impact of different degrees of damage on the temperature and stress field distribution characteristics using finite element analysis methods. The research results show that the initial stage of damage is characterized by wall cracking with the thinning of the dovetail groove the furnace shell temperature rises the temperature difference of cooling water increases the cooling efficiency gradually deteriorates and the stress concentration in the cracks intensifies when developing to the state of exposed water pipes the cooling efficiency drops sharply the area around the exposed water pipes becomes a new stress concentration zone which accelerates wall spalling and water pipe erosion while refractory mud filling can only alleviate thermal shock in the short term it is difficult to completely solve the problems of insufficient cooling efficiency and long-term structural damage and the research conclusions can provide a basis for the design optimization and service life prediction of cast iron cooling staves. [ABSTRACT FROM AUTHOR]
ISSN:00092509
DOI:10.1016/j.ces.2026.123618