Heat exchange apparatus and method of use

1. A heat exchange apparatus mounted within a metallurgy furnace comprising:

an integrally formed unitary monolithic pipe defined by an inner boundary and an outer boundary, the pipe including:

a hollow core defined by the inner boundary and having a core center;

a support portion on the outer boundary, the support portion having a support center and a support length defined by a cumulative distance the support portion extends laterally on either side of the support center;

a generally planar conduction portion formed generally tangentially on the outer boundary generally opposite the support portion and extending generally laterally of the pipe, the conduction portion having a conduction center and a conduction length defined by a cumulative distance the conduction portion extends generally laterally on either side of the conduction center, the conduction length being greater than the support length; and

wherein the pipe has a vertical axis extending generally through the core center when viewed in cross section and wherein each of the support portion, the hollow core and the conduction centers are displaced from and generally aligned with one another along the vertical axis; and the support portion and the generally planar conduction portion are the same material; and

wherein the support portion is mounted within a metallurgy furnace having an operating portion such that the conduction portion is exposed to the hot metal or gases emanating from the furnace and the conduction portion is disposed facing inwardly toward the operating portion of the furnace and the support portion is coupled to the furnace wall and the support portion is disposed facing outwardly away from the operating portion of the furnace.

2. The heat exchange apparatus of claim 1 wherein the pipe comprises a unitary pipe, the conduction portion being formed integrally with the outer boundary.

3. The heat exchange apparatus of claim 2 wherein the pipe comprises a heavy walled pipe.

4. The heat exchange apparatus of claim 3 wherein the pipe comprises a metallic pipe.

5. The heat exchange apparatus of claim 4 wherein the pipe is manufactured from a metal chosen from the group consisting of a ferrous metal, steel, copper, a steel ferrous alloy, a copper alloy, nickel, titanium, a bronze alloy, an aluminum-bronze alloy, and a nickel-bronze alloy.

6. The heat exchange apparatus of claim 4 wherein the pipe is manufactured from a process chosen from the group consisting of cold rolling, hot rolling, drawing, extruding and casting.

7. The heat exchange apparatus of claim 4 wherein the unitary pipe is extruded.

8. The heat exchange apparatus of claim 7 wherein the support portion comprises a generally planar portion.

9. The heat exchange apparatus of claim 7 wherein the support portion is generally non-planar.

10. The heat exchange apparatus of claim 9 wherein the support portion is arcuate.

11. The heat exchange apparatus of claim 7 wherein the pipe comprises a first half including the conduction portion and having a first mass and a second half including the support portion and having a second mass, the first mass and the second mass being substantially equivalent.

12. The heat exchange apparatus of claim 4 further comprising:

a cooling panel comprising a plurality of the pipe in fluid communication with each other; and

wherein the cooling panel is disposed within the metallurgy furnace with the conduction portion of each pipe facing inwardly toward the operating portion of the furnace.

13. The heat exchange apparatus of claim 12 wherein the plurality of pipe is coupled together.

14. The heat exchange apparatus of claim 13 wherein the conduction portion of each of the plurality of pipe includes a pair of opposing protrusions extending from the conduction center and ending in a tip, the tip of each of the opposing protrusions being coupled to the corresponding tip of the adjacent pipe forming a continuous surface.

15. The heat exchange apparatus of claim 12 wherein the supporting portion of each pipe is connected directly to the metallurgical furnace.

16. The heat exchange apparatus of claim 12 wherein the supporting portion of each pipe is connected to a plate and the plate is connected to the furnace.

17. The heat exchange apparatus of claim 12 wherein the conduction portion comprises a substantially flat smooth surface continuous between pipes.

18. The heat exchange apparatus of claim 12 wherein the conduction portion comprises at least one notch.

19. The heat exchange apparatus of claim 12 wherein the conduction portion of at least one pipe comprises a substantially smooth surface and the conduction portion of at least one other pipe comprises at least one notch.

20. A method of cooling the interior wall of a metallurgical furnace comprising the steps of:

forming a plurality of monolithic pipes with each pipe comprising a tubular section, a generally arcuate support portion, and a generally planar conduction portion generally opposed to the support portion; the support portion and the generally planar portion are the same material;

mounting the plurality of monolithic pipes in the metallurgical furnace so that the generally planar conduction portions of the pipes are coupled and disposed facing inwardly toward the operating portion of the furnace so that the generally planar conduction portions of the pipes form a generally planar portion exposed to the hot metal or gases emanating from the furnace and each pipe support portion is coupled to the furnace wall and the support portion is disposed facing outwardly away from the operating portion of the furnace; and

directing a cooling fluid through the pipes.

21. The method of cooling of claim 20 wherein the conduction portion of each pipe of the panel comprises a notched surface and further comprising the step of retaining transient matter from the furnace on the conduction portion.

22. The method of cooling of claim 20 wherein the conduction portion of each pipe of the panel comprises a substantially smooth surface and further comprising the step of discouraging the retention of transient matter from the furnace on the substantially smooth conduction surface.

23. The method of cooling of claim 20 wherein at least one pipe of the panel has a substantially smooth conduction portion and at least one pipe of the panel has a notched conduction portion and further comprising the steps of

discouraging the retention of transient matter from the furnace on the substantially smooth conduction portion; and

retaining transient matter from the furnace on the notched conduction portion.

24. The method of claim 23 further comprising the step of replacing one or more of the pipes.

25. The method of claim 20 wherein the generally planar portion is continuous between pipes.

26. The method of claim 20 wherein the generally planar conduction portion of each of the plurality of pipes includes a pair of opposing protrusions extending from a conduction center and ending in a tip, and further comprising the step of abutting the tip of opposing protrusions and coupling the abutting corresponding tips of adjacent pipe to form a continuous surface.