Numerical Investigation on the Heat Transfer Performance of a Copper‐Bar‐Embedded Cast Iron Cooling Stave for Blast Furnaces

Blast furnace ironmaking is a high‐temperature process in which cooling staves are essential for protecting the furnace shell and lining and extending furnace life. Cast iron cooling staves are widely used because of heat resistance, mechanical strength, low cost, and mature manufacturing, but their low thermal conductivity limits cooling performance. To improve heat transfer, a novel cast iron cooling stave embedded with three copper bars containing water channels was proposed. A three‐dimensional model was established to compare conventional and modified staves. Results showed that the new design reduced the maximum and average hot surface temperatures by 6°C and 42°C, respectively, and reduced the air‐gap‐induced rise in these temperatures from 58°C to 40°C and from 63°C to 27°C. Higher edge gas flow temperature increased refractory temperature, whereas slag crust formation reduced the maximum temperature by up to 50%. For stable slag crust formation and longer furnace life, cooling water velocity should be maintained at 1.5–2.0 m/s, because lower velocity gives insufficient cooling and higher velocity offers limited additional cooling benefit and lower economic efficiency, while edge gas flow temperature should remain stable.