Water-Cooled Tubular Compensator
Product Overview
Water-cooled tubular compensator (metallurgical electric furnace
dedicated water-cooled expansion joint integrating conductivity and
cooling) serves as the core integrated conductive & cooling fitting
for the short net system of submerged arc furnaces, electric arc
furnaces and refining furnaces. It is installed between the
secondary outlet copper tube of furnace transformers and the
front-furnace conductive copper tubes of the short net, combining
four major functions: high-current conduction, circulating water
cooling, multi-dimensional displacement compensation and vibration
damping.
Adopting a double-layer tubular sandwich water cooling structure,
its conductive body is made of high-purity copper. Circulating
cooling water continuously dissipates Joule heat generated by heavy
current and radiant high temperature from the furnace. Meanwhile,
it absorbs axial displacement caused by thermal expansion and
contraction, assembly errors from on-site installation, and
alternating electromagnetic vibration during smelting. This
prevents stress cracking, water leakage and conductive burnout of
short net copper tubes and transformer copper bars, ensuring
24-hour continuous stable operation of smelting systems. It is an
indispensable safety matching component for high-load metallurgical
electric furnace short nets.
Structural Composition
Inner Conductive Tube (Main Conductive Layer)
Seamless T2 high-purity copper tube with high conductivity and low
resistance, bearing the ultra-large operating current on the
secondary side of electric furnaces and directly contacting cooling
medium. Integrally forged flanges or taper sleeve conductive joints
are formed at both ends with silver-plated contact surfaces to cut
contact resistance and reduce ablation from heat generation.
Water-Cooled Sandwich Cavity
A sealed water circulation interlayer formed by fully welded inner
and outer tubes, equipped with water inlet and outlet nozzles.
Cooling water circulates all around the conductive copper tube
without cooling dead zones, rapidly removing conductive heat and
radiant high temperature from furnaces.
Sliding Expansion & Compensation Mechanism
Precision-fit telescopic section of the inner tube allows free
axial expansion and contraction, matched with a guiding limit
anti-drop structure to avoid water leakage caused by tearing under
ultimate tension; it supports compensation of minor radial and
angular offset.
Insulating Protective Outer Layer
High-strength high-temperature resistant fiberglass insulating
sheath, isolating short circuits of external metal components,
insulating heat and preventing scalding to lower on-site risks of
burns.
Fastening & Sealing Assemblies
Heat-resistant rubber gaskets and high-strength stainless steel
bolts achieve multi-layer sealing on flange surfaces, with no
leakage under long-term high-temperature vibration working
conditions. An elongation observation mark is attached to visually
check the telescopic compensation status.
Core Technical Parameters
General Specifications
| Parameter Item | Standard Technical Index | Customizable Extended Range |
|---|
| Conductive Material | T2 High-Purity Copper | Oxygen-Free Copper, Silver-Plated Copper (Heavy-Duty Model for High
Current) |
| Conductive Cross-Sectional Area | 300～3200mm² | Custom oversized section up to 3500/4000mm² |
| Adaptable Operating Current | 1000A～35000A | Max. support 50000A for submerged arc furnace short nets |
| Compensation Mode | Axial compensation primarily, minor radial & angular compensation | Custom bidirectional telescopic model |
| Standard Compensation Stroke | ±50mm, ±80mm, ±120mm | Max. telescopic stroke ±150mm on demand |
| Cooling Water Circuit | Full-area double-layer sandwich water cooling | Two structures: double-side water inlet/outlet, single inlet &
single outlet |
| Cooling Water Pressure | 0.2～0.4MPa | Max. bearing pressure 0.6MPa |
| Inlet Cooling Water Temperature | ≤35℃ | Softened circulating water matched for high-temperature working
conditions |
| Ambient Operating Temperature | -20℃～650℃ | Reinforced heat insulation model for areas close to
high-temperature furnaces |
| Connection Type | Flange bolt connection, taper sleeve clamp connection | Custom quick plug-in, welded flanges |
| Insulation Withstand Voltage | ≥3kV power frequency withstand voltage | Can be upgraded to 5kV for high-voltage short nets |
| Standard Overall Length | 600/800/1000/1200mm | Custom length from 400mm to 2000mm |
| Applicable Medium | Softened circulating cooling water | Pure water, closed-circuit chilled water |
Key Performance Indicators
- Contact Resistance: ≤0.03μΩ (lower for silver-plated joints to
reduce heat loss)
- Cooling Efficiency: Single unit heat dissipation capacity 15～120kW
per hour, eliminating overheating and red-hot copper bodies
- Vibration Resistance: Withstand alternating electromagnetic
vibration during smelting without loose joints or water leakage in
continuous operation
- Service Life: ≥5 years under normal soft water working conditions,
extendable to over 8 years with regular maintenance
Core Product Advantages (Promotional Selling Points)
1. Integrated Conduction & Water Cooling for Energy Saving
Full coverage double-layer sandwich water cooling eliminates local
high-temperature dead zones, greatly lowering temperature rise of
the entire short net system and reducing reactive power loss of
transformers and copper bars. Compared with ordinary bare copper
flexible connectors, it cuts power consumption by 8%～15% and avoids
shutdown failures caused by burnout of conductive parts.
2. Multi-Dimensional Displacement Compensation to Eliminate
Equipment Stress
Solves three major working condition challenges simultaneously:
① Axial expansion and contraction induced by high-temperature
thermal expansion and cold contraction;
② Assembly deviations from equipment installation and civil
engineering foundations;
③ Sustained vibration generated by alternating electromagnetic
force during smelting.
It protects welds of transformers and conductive copper tubes from
stress damage and sharply cuts maintenance frequency.
3. High Conductivity & Low Loss, Suitable for Ultra-Large Current
Integrally formed seamless T2 copper with sufficient conductive
cross-section. Silver-plated surfaces on flanges at both ends
deliver ultra-low contact resistance, with controllable temperature
rise under heavy current. It matches submerged arc furnaces for
ferrosilicon, silicomanganese, ferrovanadium, yellow phosphorus and
calcium carbide as well as steelmaking electric arc furnaces under
high-load conditions.
4. Reliable Sealing for Long-Term Leak-Free Operation
Full welding process for sandwich cavities plus composite
multi-layer flange sealing resists alternating cold and heat and
continuous vibration, eliminating hidden risks of seepage and
dripping water. A limit anti-tension structure prevents cavity
tearing under maximum telescopic travel, avoiding production
shutdowns due to water leakage during continuous smelting.
5. Compact Structure, Easy Installation & Maintenance
Integral tubular design occupies minimal space, adapting to narrow
front-furnace short net layouts. No external water cooling hoses
are required; electric and water circuits can be connected
synchronously on site, with disassembly and assembly completed
simply by removing flange bolts. Worn sealing parts can be replaced
separately instead of the whole compensator, cutting operation and
maintenance costs significantly.
6. Full-Condition Customization for All Types of Metallurgical
Furnaces
Customizable cross-section, length, compensation stroke, water
inlet/outlet layout and flange dimensions to match furnaces ranging
from small refining furnaces to large-scale 10,000 kVA submerged
arc furnaces. Complete sets of short net accessories including
water-cooled cables, conductive cross arms and taphole openers can
be supplied together.
Applicable Industries & Matching Equipment
- Ferrous Alloy Smelting: Short net systems of submerged arc furnaces
for ferrosilicon, silicomanganese, ferrochrome, ferrovanadium and
ferronickel
- Calcium Carbide & Yellow Phosphorus: Secondary conductive
connections of large closed submerged arc furnaces
- Steelmaking: Short net conductive cooling of AC/DC electric arc
furnaces and LF ladle refining furnaces
- Non-Ferrous Smelting: High-current conductive systems of copper,
aluminum, lead-zinc smelting furnaces and reduction furnaces
- Matching Accessories: Electric furnace transformers, water-cooled
conductive copper tubes, water-cooled cables, conductive cross arms
and complete short net fittings
Product Selection Guidelines
- Core selection parameters: Rated secondary current of furnace
transformer, outer diameter of short net copper tube, reserved
on-site installation length, required telescopic compensation
stroke, cooling water supply pressure
- For heavy-duty working conditions (current＞25000A), select upgraded
models with silver-plated flanges and enlarged water-cooled
interlayers to reduce heat generation
- For areas adjacent to high-temperature furnace bodies, choose
models with thickened high-temperature resistant fiberglass
insulating sheaths
- For factories with high water hardness, a soft water circulation
system is recommended to extend the service life of internal water
channels of the compensator
Promotional Headlines
- Water-Cooled Tubular Compensator | Integrated Conductive & Cooling
Expansion Joint for Metallurgical Electric Furnace Short Nets
- High-Current Water-Cooled Compensator, Special Displacement &
Vibration Absorbing Device for Submerged Arc Furnaces & Electric
Arc Furnaces
- Double-Layer Sandwich Water-Cooled Tubular Compensator, Efficient
Cooling to Prevent Overheating & Thermal Expansion Compensation
Against Water Leakage
- Custom Water-Cooled Tubular Compensator, Compatible with All
Industrial Smelting Electric Furnaces from 1000A to 50000A
Brief English Introduction for Foreign Trade Official Website
Water-Cooled Tubular Compensator
The water-cooled tubular compensator is an integrated conductive
and cooling fitting specially designed for the short net system of
submerged arc furnaces, electric arc furnaces and refining
furnaces. It is installed between the secondary copper tube of
furnace transformers and the conductive copper tubes on the furnace
front.
Adopting a double-layer tubular water cooling sandwich structure
with T2 high-purity copper as the conductive body, circulating
cooling water continuously removes Joule heat and radiant high
temperature from furnaces. It absorbs axial displacement from
thermal expansion, installation deviations and electromagnetic
vibration, avoiding stress cracking and burnout of short net copper
tubes and transformer copper bars.
Customizable conductive cross-section, compensation stroke, overall
length and connection modes. Widely applied in smelting furnaces
for ferroalloy, calcium carbide, steelmaking and non-ferrous
metals. It runs stably under harsh working conditions of heavy
current and high temperature, lowering power consumption and
maintenance costs.
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