The transition shaft jackets shown are used on the critical bottom section of the reaction shaft. These jackets are made with double compartment monel pipe coil assemblies and are precision machined to insure a complete enclosed ring. (See inset photo for single jacket).
This set of copper jackets with monel pipe coil assemblies replaces refractory bricks/linings in a horizontal reaction melting furnaces. The exact locations of cast-in thermowells are essential for monitoring operating temperatures. The use of non-destructive testing techniques, include conductivity, chemical analysis, ultra-sonic, hydrostatic and flow testing as well as radiographic examination. This battery of tests are used to insure a high quality product that meets or exceeds customer specifications. The different types of copper jackets can also be cast with cored water passages utilizing a specially developed sand system. The same testing procedures are used on the cored passage design.
The slag and taphole blocks with monel pipe coil assemblies can be manufactured as a one piece or multiple piece designs. The reverse tapered refractory grooves in the taphole are cast in place to very close tolerances. With perimeter final machining and cold face machining at the taphole itself, specialized mounting can be achieved for the block or for required face plates.
Falcon manufactures cast copper launders with monel pipe coil assemblies and with cast-in refractory pockets, up to 10,000 pounds finished weight. (This launder is approximately 6000 pounds)
Falcon has developed casting techniques which result in fusion between the monel coil and the copper casting. This cut cross-section depicts the metallurgical bond achieved between the coil and the casting resulting in optimal heat transfer.

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