WO2013009824A1 - Constructions en douve et briques équipées de témoins d'usure réfractaires et de thermocouples de processus - Google Patents
Constructions en douve et briques équipées de témoins d'usure réfractaires et de thermocouples de processus Download PDFInfo
- Publication number
- WO2013009824A1 WO2013009824A1 PCT/US2012/046193 US2012046193W WO2013009824A1 WO 2013009824 A1 WO2013009824 A1 WO 2013009824A1 US 2012046193 W US2012046193 W US 2012046193W WO 2013009824 A1 WO2013009824 A1 WO 2013009824A1
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- WIPO (PCT)
- Prior art keywords
- stave
- brick
- bricks
- channels
- construction
- Prior art date
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D1/00—Casings; Linings; Walls; Roofs
- F27D1/12—Casings; Linings; Walls; Roofs incorporating cooling arrangements
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B7/00—Blast furnaces
- C21B7/04—Blast furnaces with special refractories
- C21B7/06—Linings for furnaces
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B9/00—Stoves for heating the blast in blast furnaces
- C21B9/02—Brick hot-blast stoves
- C21B9/06—Linings
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
- C21C5/28—Manufacture of steel in the converter
- C21C5/42—Constructional features of converters
- C21C5/44—Refractory linings
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B1/00—Shaft or like vertical or substantially vertical furnaces
- F27B1/10—Details, accessories, or equipment peculiar to furnaces of these types
- F27B1/12—Shells or casings; Supports therefor
- F27B1/14—Arrangements of linings
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
- F27D21/0021—Devices for monitoring linings for wear
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
- F27D21/02—Observation or illuminating devices
Definitions
- This invention relates generally to apparatus and methods for constructing and installing bricks, such as refractory bricks, in frames, staves and/or coolers in blast furnaces or other metallurgical furnaces.
- Related fields include systems and methods for cooling blast furnaces and other metallurgical furnaces.
- Related fields include cooling plates and cooling staves.
- This invention also relates generally to apparatus and methods for monitoring the wear of refractory, refractory bricks in frames, staves and or coolers in blast furnaces or other metallurgical furnaces.
- the furnace wear monitor aspect of the invention includes a monitor and thermocouple probes embedded in refractory coupled with comparative laser optical scans of the refractory surface on the interior of the furnace.
- Conventional designs and constructions for cooling refractory bricks in blast furnaces and other metallurgical furnaces include cooling staves.
- Conventional copper cooling staves are generally planar, rectangularly shaped and arranged within a furnace substantially parallel or as parallel as possible, given the shapes of the staves and/or the interior of the furnace, to the metal shell of the furnace.
- the cooling staves typically cover a high percentage of the inner surface of the metal shell of the furnace.
- Refractory lining, such as refractory bricks may be disposed in, on or around the surface of the stave, such as, for example, bricks disposed within slots or channels defined by the stave.
- Staves also have cavities that provide passages or house internal piping.
- Such passages or piping are connected to one or more external pipes that extend from the furnace shell side of the stave and penetrate the metal shell of the furnace. Coolant, such as, for example, water at an elevated pressure is pumped through the pipes and passages in order to cool the stave. The cooled stave thus cools the refractory bricks disposed within slots or channels defined by the stave.
- the ram gap often erodes prematurely and furnace gases track between the staves.
- conventional stave/brick constructions leave brick edges protruding into the furnace which are exposed to matter and other debris falling through the furnace.
- Such protruding brick edges tend to wear out more frequently than non-protruding edges, leading to broken or crumbled bricks that may fall through the furnace causing further damage to the furnace lining.
- Such broken bricks also expose the stave thereby causing it to be damaged or worn out prematurely.
- Strimple 's monitor discloses the use of a conductor and sheath made from any electrically conductive metal capable of withstanding the hostile environments prevalent in metallurgical apparatus, for example a blast furnace, basic oxygen furnace or an electric furnace.
- the refractory monitor determines changes in refractory thickness by detecting the impedance variations dependent upon the capacitance between the conductor and the sheath and is dependent on the dielectric constant to function. Therefore, this monitor must undergo extensive customization and the dielectric constant of the refractory material must be balanced with the monitor.
- optical scanning methods of mapping the refractory of the interior of blast furnaces that employ lasers with optical detectors capable of detecting scattered laser rays.
- blowout When a blowout occurs it can allow the molten metal to flow like water from the furnace causing the destruction of nearly everything in its path. Such blowouts can kill or severely hurt furnace workers. Moreover, blowouts can cause the closure of mills for many months putting people out of work while mills are repaired or rebuilt, additionally even completely closing mills if the disaster is severe enough.
- the present invention is directed to a technology for measuring the thickness of refractory wall in a blast furnace or other type of metallurgical apparatus and, more specifically, to measuring the thickness of a refractory wall of a stave/brick construction comprising a stave having a plurality of ribs and a plurality of channels, wherein a front face of the stave defines the first opening into each of the channels and a plurality of bricks wherein each brick is insertable into one of the plurality of channels via its first opening to a position, upon rotation of the brick, partially disposed in the one channel such that one or more portions of the brick at least partially engage one or more surfaces of the one channel and/or of a first rib of the plurality of ribs whereby the brick is locked against removal from one channel through its first opening via linear movement without first being rotated.
- the present invention preferably employs wear monitors comprising a central metallic conductor and an outer metallic sheath separated from the conductor by a fine close- packed insulating material having a desirable dielectric constant.
- the device having two ends, a refractory end and a system end.
- the system end may be lead to a junction box and be connected to an electrical connector means attached thereto or may be connected directly to the electrical connector means by which the device is connected to an electronic instrument which uses time-domain reflectometry techniques.
- the method of this invention foresees multiple electrodes being inserted around the critical wear zone of the furnace. As the refractory in the furnace erodes, the refractory end of the wear monitor end of the monitoring device also erodes at substantially the same rate as the refractory.
- the loss in length of the monitoring device is substantially equal to the loss of the refractory because the original thickness of the refractory and the position of the refractory end of the wear monitor can be deduced at any time from the length of the monitoring device displayed on the recording equipment. This is accomplished by subtracting the displayed length of the monitoring device from the original displayed length determined along with a suitable calibration of the recording instrument and in turn subtracting the difference determined from the known thickness of the original refractory. Alternatively said, the erosion or loss in thickness of the refractory is equal to the loss of the embedded wear monitor.
- a third aspect of the present invention is providing a laser optical scan of the furnace refractory interior surface profile measuring method whereby the laser scan provides a clear mapping for determination of any significant changes that take place in non-critical wear regions by providing a laser light emitter and a receiver to scan the interior where the profile measurements are detected through triangulation methods.
- the refractory bricks may be installed in a flat or curved stave or cooler, before or after the stave cooler is installed in a furnace. Additionally, in the event of a reworking or rebuilding of the stave brick construction in the furnace, the refractory bricks of the present invention can be replaced or re-installed in-whole or in-part, without removing the stave or cooler from the furnace.
- a stave/refractory brick construction in which the refractory bricks can be installed in a stave or cooler that is tilted on an angle with the bricks staying in the grooves in such stave or cooler and in which the bricks may be inserted and/or removed from the front face of the stave before and/or after the stave is installed in the furnace.
- a stave/refractory brick construction in which the refractory bricks are doubly locked into the channels in the stave (1) by complementary surfaces of the bricks and stave channels that are engaged by inserting a portion of each brick into a channel or groove in the stave and simultaneously or thereafter rotating each brick on an axis substantially parallel to a plane of the stave and/or (b) such that the bottom of the brick rotates in a direction towards or substantively towards the stave in order to engage such complementary surfaces of the channel and brick in order to secure or lock the brick into the channel chamber and prevent it from moving linearly out of the channel or groove through an opening in the front face of the stave and (2) by oblique or tapered sections of the bricks that expand when heated during furnace operation, and push against the stave or cooler to maintain an effective bond therewith thereby providing highly effective cooling of the bricks, while also holding in place any bricks that might crack or break.
- stave/refractory brick construction utilizing bricks having an increased vertical or neck thickness to increase strength and make the bricks less susceptible to cracking while also allowing the bricks to be installed faster, with the additional weight of each brick helping to keep it in place and less susceptible to failure.
- an improved stave/refractory brick construction having a single layer of bricks in tight contact with the stave to eliminate thermal barriers associated with conventional stave/brick constructions having multiple layers and/or multiple mortar joints.
- the present invention comprises a stave/brick construction, comprising: a stave having a plurality of ribs and a plurality of channels, wherein a front face of the stave defines a first opening into each of the channels; and a plurality of bricks wherein each brick is insertable into one of the plurality of channels via its first opening to a position, upon rotation of the brick, partially disposed in the one channel such that one or more portions of the brick at least partially engage one or more surfaces of the one channel and/or of a first rib of the plurality of ribs whereby the brick is locked against removal from the one channel through its first opening via linear movement without first being rotated.
- the stave may define one or more side openings into each of the channels.
- the one or more portions of the brick comprises a nose at least partially disposed in a first section of the one channel, which is preferably complementary to the nose, i addition, rotation of the brick comprises a bottom of the brick moving in a direction towards the stave.
- a first rib surface of the first rib preferably is complementary to a groove defined by a top of the brick and the first rib surface is at least partially disposed in the groove.
- each of the plurality of bricks can be removed from its respective channel via rotation of each brick comprising a bottom of each brick moving in a direction away from the stave.
- the stave is preferably either substantially flat or curved with respect to one or both of a horizontal axis and a vertical axis of the stave.
- the stave houses a plurality of pipes.
- the plurality of bricks at least partially disposed in the plurality of channels form a plurality of stacked, substantially horizontal rows of bricks protruding from the front face of the stave, where the plurality of bricks comprise exposed faces that preferably define a flat surface or uneven surface.
- one of the bricks cannot be pulled and/or rotated out of the first opening of its respective channel when another brick is disposed in the row above and partially or completely covers the one brick.
- the stave/brick construction comprises a plurality of staves standing side-by-side with gaps between adjacent staves; wherein each stave has a plurality of ribs, a plurality of channels, and a plurality of substantially horizontal rows of bricks disposed in the plurality of channels.
- the plurality of substantially horizontal rows of bricks disposed in the plurality of channels covers, in-whole or in-part, the gaps between adjacent staves.
- the staves stand substantially vertically or at an angle other than about 90 degrees.
- each of the plurality of bricks further defines a seat wherein the seat is at least partially disposed in a second section of the one channel and preferably the second section is complementary to the seat.
- each of the plurality of bricks comprises an oblique top section and an oblique bottom section, wherein each of the oblique top and bottom sections protrude from the face of the stave and preferably the oblique top and bottom sections of each brick are substantially parallel to each other.
- the plurality of bricks at least partially disposed in the plurality of channels form a plurality of stacked, substantially horizontal rows of bricks protruding from the front face of the stave; and wherein the oblique top section of one brick is disposed substantially near, adjacent to, in partial contact with or in complete contact with the oblique bottom section of another brick immediately above the one brick.
- the stave/brick construction of the present invention further comprises means for operatively connecting a thermocouple to the stave.
- the present invention comprises a frame/brick construction, comprising: a frame having a plurality of ribs and a plurality of channels, wherein a front face of the frame defines a first opening into each of the channels; and a plurality of bricks wherein each brick is insertable into one of the plurality of channels via its first opening to a position, upon rotation of the brick, partially disposed in the one channel such that one or more portions of the brick at least partially engage one or more surfaces of the one channel and/or of a first rib of the plurality of ribs whereby the brick is locked against removal from the one channel through its first opening via linear movement without first being rotated.
- the frame may define one or more side openings into each of the channels.
- the one or more portions of the brick comprises a nose at least partially disposed in a first section of the one channel, which is preferably complementary to the nose.
- rotation of the brick comprises a bottom of the brick moving in a direction towards the frame.
- a first rib surface of the first rib preferably is complementary to a groove defined by a top of the brick and the first rib surface is at least partially disposed in the groove.
- each of the plurality of bricks can be removed from its respective channel via rotation of each brick comprising a bottom of each brick moving in a direction away from the frame.
- the frame is preferably either substantially flat or curved with respect to one or both of a horizontal axis and a vertical axis of the frame.
- the plurality of bricks at least partially disposed in the plurality of channels form a plurality of stacked, substantially horizontal rows of bricks protruding from the front face of the frame, where the plurality of bricks comprise exposed faces that preferably define a flat surface or uneven surface.
- one of the bricks cannot be pulled and/or rotated out of the first opening of its respective channel when another brick is disposed in the row above and partially or completely covers the one brick.
- the frame/brick construction comprises a plurality of frames standing side-by-side with gaps between adjacent frames; wherein each frame has a plurality of ribs, a plurality of channels, and a plurality of substantially horizontal rows of bricks disposed in the plurality of channels.
- the plurality of substantially horizontal rows of bricks disposed in the plurality of channels covers, in-whole or in-part, the gaps between adjacent frames.
- the frames stand substantially vertically or at an angle other than about 90 degrees.
- each of the plurality of bricks further defines a seat wherein the seat is at least partially disposed in a second section of the one channel and preferably the second section is complementary to the seat.
- each of the plurality of bricks comprises an oblique top section and an oblique bottom section, wherein each of the oblique top and bottom sections protrude from the face of the frame and preferably the oblique top and bottom sections of each brick are substantially parallel to each other.
- the plurality of bricks at least partially disposed in the plurality of channels form a plurality of stacked, substantially horizontal rows of bricks protruding from the front face of the frame; and wherein the oblique top section of one brick is disposed substantially near, adjacent to, in partial contact with or in complete contact with the oblique bottom section of another brick immediately above the one brick.
- the present invention comprises a method for assembling a stave/brick construction comprising: providing a stave in a standing position, wherein the stave has a plurality of ribs and a plurality of channels, wherein a front face of the stave defines a first opening into each of the channels; and inserting a plurality of bricks into each channel via its first opening so that a first portion of each brick enters its respective channel via its first opening; and rotating each brick so that it is partially disposed in its respective channel with its first portion at least partially engaged with one or more surfaces of its respective channel and/or of a first rib of the plurality of stave ribs whereby the brick is locked against linear movement out of the one channel through its first opening.
- the method for assembling a stave/brick construction of the present invention further comprises: removing one or more of the plurality of bricks from their respective channels via rotation of the one or more bricks comprising a bottom of each brick moving in a direction away from the stave.
- the present invention comprises a brick for a stave/brick construction, comprising: a top section defining a nose contiguous with a locking side of the brick and an upper oblique section contiguous with a first face of the brick, wherein the locking side comprises the nose, a second face, a seat and a lower concave section; and a bottom defining a lower oblique section contiguous with the first face of the brick.
- brick may further comprise a groove defined by the top section disposed across a width of the brick.
- the second face extends from the nose to the seat and is opposite to the first face. Also, preferably, a height of the second face is equal to or greater than about two times a depth of the brick measured from the second face to a bottom of the groove.
- one or both of the nose and seat may be arcuate, polygonal or angular.
- one or both of the first and second faces of the brick preferably are substantially flat.
- the present invention comprises a stave/brick construction, comprising: a stave having a plurality of ribs and a plurality of channels, wherein a front face of the stave defines a first opening into each of the channels and wherein the plurality of ribs comprises one or more short ribs each of which is shorter than one or more adjacent long ribs, wherein each short rib and at least one adjacent long rib define, at least in part, a void such that the stave defines a plurality of voids; and a plurality of bricks wherein each brick is insertable into one of the plurality of voids in a direction substantially perpendicular to the front face to a first position from which it can be slid to a second position within one of the plurality of channels.
- the present invention comprises a stave/brick construction, comprising: a stave having a plurality of ribs and a plurality of channels, wherein a front face of the stave defines a first opening into each of the channels; a plurality of bricks wherein each brick is insertable into one of the plurality of channels via its first opening to a position, upon rotation of the brick, partially disposed in the one channel such that one or more portions of the brick at least partially engage one or more surfaces of the one channel and/or of a first rib of the plurality of ribs whereby the brick is locked against removal from the one channel through its first opening via linear movement without first being rotated; and one or more wear monitors, wherein each wear monitor is disposed through or adjacent to the stave and/or one or more of the bricks.
- each of the wear monitors comprises a metallic conductor coax and an outer metallic sheath separated by refractory material.
- each of the wear monitors may be read using a time-domain reflectometer and/or time-domain reflectometry.
- the frame/brick construction of the present invention further comprises one or more thermocouples disposed through or adjacent to the stave and/or one or more of the bricks.
- wear monitors and thermocouples are read periodically and/or automatically via computer.
- the plurality of bricks at least partially disposed in the plurality of channels form a plurality of stacked, substantially horizontal rows of bricks protruding from the front face of the stave.
- one of the bricks cannot be pulled and/or rotated out of the first opening of its respective channel when another brick is disposed in the row above and partially or completely covers the one brick.
- the frame/brick construction of the present invention further comprises a plurality of staves standing side-by-side with gaps between adjacent staves; wherein each stave has a plurality of ribs, a plurality of channels, and a plurality of substantially horizontal rows of bricks disposed in the plurality of channels.
- the plurality of substantially horizontal rows of bricks disposed in the plurality of channels covers, in- whole or in-part, the gaps between adjacent staves.
- the frame/brick construction of the present invention further comprises a laser emitter/receiver for taking readings by emitting one or more laser pulses onto the stave and/or plurality of bricks and for receiving the one or more laser pulses as reflected from the stave and/or plurality of bricks, and a computer for analyzing the reflected laser pulses to determine one or more conditions of the stave and/or plurality of bricks and/or differences in the one or more conditions of the stave and/or plurality of bricks between first and second readings.
- the rotation of the brick comprises a bottom of the brick moving in a direction towards the stave.
- the stave is substantially flat.
- the stave is curved with respect to one or both of a horizontal axis and a vertical axis.
- each of the plurality of bricks comprises an oblique top section and an oblique bottom section, wherein each of the oblique top and bottom sections protrude from the face of the stave; the oblique top and bottom sections are substantially parallel and/or the plurality of bricks at least partially disposed in the plurality of channels form a plurality of stacked, substantially horizontal rows of bricks protruding from the front face of the stave; and/or the oblique top section of one brick is disposed substantially near, adjacent to, in partial contact with or in complete contact with the oblique bottom section of another brick immediately above the one brick.
- the plurality of bricks comprise exposed faces that define a flat or uneven surface.
- the present invention comprises a stave/brick construction, comprising: a plurality of staves standing side-by-side defining gaps between adjacent staves, wherein each stave has a plurality of ribs and a plurality of channels, wherein a front face of each stave defmes a first opening into each of the channels, wherein each stave is curved with respect to one or both of a horizontal axis and a vertical axis; a plurality of bricks wherein each brick is insertable into one of the plurality of channels via its first opening to a position, upon rotation of the brick, partially disposed in the one channel such that one or more portions of the brick at least partially engage one or more surfaces of the one channel and/or of a first rib of the plurality of ribs whereby the brick is locked against removal from the one channel through its first opening via linear movement without first being rotated; wherein the plurality of bricks at least partially disposed in the plurality of channels form a plurality of stacked
- the frame/brick construction of the present invention further comprises a laser emitter/receiver for taking readings by emitting one or more laser pulses onto the staves and/or plurality of bricks and for receiving the one or more laser pulses as reflected from the staves and/or plurality of bricks, and a computer for analyzing the reflected laser pulses to determine one or more conditions of the staves and/or plurality of bricks and/or differences in the one or more conditions of the staves and/or plurality of bricks between first and second readings.
- a laser emitter/receiver for taking readings by emitting one or more laser pulses onto the staves and/or plurality of bricks and for receiving the one or more laser pulses as reflected from the staves and/or plurality of bricks
- a computer for analyzing the reflected laser pulses to determine one or more conditions of the staves and/or plurality of bricks and/or differences in the one or more conditions of the staves and/or plurality
- FIG. 1 is a front perspective view of a conventional stave;
- FIG. 2 is a side perspective view of a conventional, dove-tailed refractory brick;
- FIG. 3 is a side perspective view of a brick according to a preferred embodiment of the present invention.
- FIG. 4 is a top perspective view of a preferred embodiment of a furnace lining of the present invention comprising a preferred embodiment of a stave/brick construction of the present invention employing the brick of FIG. 3;
- FIG. 5 is a side perspective view of a preferred embodiment of a furnace lining of the present invention comprising a preferred embodiment of a stave/brick construction of the present invention employing the brick of FIG. 3;
- FIG. 6 is a cross-sectional view of a preferred embodiment of a stave/brick construction of the present invention employing the brick of FIG. 3;
- FIG. 7 is a cross-sectional view of a preferred embodiment of a stave/brick construction of the present invention showing the brick of FIG. 3 as it is being inserted or removed from a front face of a preferred embodiment of a stave of the present invention;
- FIG. 8 is a cross-sectional view of a preferred embodiment of an alternative stave/brick construction of the present invention employing at least two different sizes of the bricks of FIG. 3.
- FIG. 9 is a top plan view of a conventional furnace lining employing conventional stave brick constructions
- FIG. 10 is a top plan view of a preferred embodiment of a furnace lining of the present invention comprising a preferred embodiment of a stave/brick construction of the present invention employing the brick of FIG. 3;
- FIG. 11 is a cross-sectional view of another preferred embodiment of a stave/brick construction of the present invention.
- FIG. 12 is a partial, front elevational view of the stave brick construction of FIG. 11.
- FIG. 13 is a furnace interior-side view of refractory wall with holes for receiving a preferred wear monitor and/or thermocouple according to the present invention.
- FIG. 14 is partial plan view showing a preferred wear monitor and thermocouple of the present invention installed in a ram joint between two staves.
- FIG. 15 is a cross sectional view of a stave/brick construction incorporating a preferred wear and temperature monitoring system of the present invention.
- FIG. 16 is a sectional plan view and close up of section 101R-S of FIG. 15.
- FIG 17 is a side plan view representation of a laser emitter/receiver used in conjunction with and part of a preferred wear and temperature monitoring system of the present invention.
- FIG. 18 is a side view representation of the refractory wall and stave construction of the present invention with thermocouple and wear monitor installed in an alternate embodiment of the present invention.
- FIG. 19 is a furnace wall view of the refractory wear monitor and thermocouple installed in an alternate embodiment of the present invention.
- FIG. 1 illustrates a planar, fluid cooled stave 10 of known construction having a plurality of stave ribs 11 and defining a plurality of stave channels 12, both of generally rectangular cross-sections for use with bricks having matching cross-sections.
- Other stave designs of known construction employ stave ribs and stave channels having cross-sections complementary to the dovetail sections 16 of the conventional refractory brick 14 shown in FIG. 2 to allow such dovetailed sections 16 thereof to be inserted into the side ends of the stave and slid into position therein with or without mortar in between each adjacent brick.
- stave/brick constructions due to the closeness to each other when installed in a furnace, such staves 10 must be removed from the furnace to allow the bricks 14 to be slid out of the stave channels 12 whenever the stave/brick construction needs to be rebuilt or repaired, either in-whole or in-part. Removing such staves 10 from the furnace is necessitated because bricks 14 cannot be removed or inserted into stave channels 12 through the front face of stave 10. As shown in FIG.
- stave 10 comprises a plurality of pipes 13 disposed inside the stave 10 which may be connected to one or more external pipes that extend from the furnace shell side of the stave 10 and penetrate the metal shell of the furnace so that coolant, such as, for example, water at an elevated pressure is pumped through the pipes 13 in order to cool the stave 10 and any refractory bricks disposed within stave channels 12 when assembled and installed in a furnace.
- coolant such as, for example, water at an elevated pressure
- FIG. 3 illustrates a preferred embodiment of a refractory brick 18 according to a preferred embodiment of a stave/brick construction 28 of the present invention.
- Brick 18 has an exposed face 26 and oblique or slanted top and bottom sections 19 and 20, respectively.
- Brick 18 also comprises or defines a locking side 29 comprising concave groove 22, a generally arcuate nose 23, a generally arcuate seat 25, a generally arcuate concave section 24, a lower face 27 and a generally planar front face 31.
- Brick 18 also has a neck 21, the vertical thickness ("ab") of which is increased with respect to the vertical neck 15 of known bricks 14.
- the length "ab" of vertical neck 21 is equal to or greater than about two (2) times the length "cd" of the depth of brick 18 that is disposed in stave channel 37 when the brick 18 is installed therein.
- the shapes, geometries and/or cross-sections of brick 18 and/or any part thereof, including, without limitation, one or more of exposed face 26, lower face 27, front face 31, oblique/slanted top section 19, oblique/slanted bottom section 20, groove 22, nose 23, seat 25, concave section 24 and front locking side 29 may be modified or take other forms such as being angular, rectilinear, polygonal, geared, toothed, symmetrical, asymmetrical or irregular instead the shapes of the preferred embodiments thereof as shown in the drawings hereof without departing from the scope of the invention hereof.
- the refractory bricks 18 of the present invention preferably may be constructed from many of the refractory materials currently available including, but not limited to, silicon carbide (such as Sicanit AL3 available from Saint-Gobain Ceramics), MgO-C (magnesia carbon), alumina, insulating fire brick (IFB), graphite refractory brick and carbon.
- refractory materials currently available including, but not limited to, silicon carbide (such as Sicanit AL3 available from Saint-Gobain Ceramics), MgO-C (magnesia carbon), alumina, insulating fire brick (IFB), graphite refractory brick and carbon.
- bricks 18 may be constructed from alternating or different materials depending upon their location in a stave 30 or within the furnace.
- the shape of bricks 18 may also be modified or altered to meet various stave and/or furnace spaces and/or geometries.
- FIGS. 3-8 and 10 Preferred embodiments of a stave/refractory brick construction 28 of the present invention is shown in FIGS. 3-8 and 10, including a preferred embodiment of a stave 30 of the present invention.
- Stave 30 may comprise a plurality of pipes (not shown), such as the pipes 13 disposed inside the stave 10 as shown in FIG. 1, which may be attached to one or more external pipes that extend from the furnace shell side of the stave 30 and penetrate the metal shell of the furnace so that coolant, such as, for example, water at an elevated pressure is pumped through such pipes (not shown) in order to cool the stave 30 and any refractory bricks 18 disposed within stave channels 37 thereof when assembled and installed in a furnace.
- coolant such as, for example, water at an elevated pressure
- the stave 30 is constructed of copper, cast iron or other metal of high thermal conductivity, while any pipes disposed within stave 30 are preferably made from steel or copper or copper alloys such as a UNS C71500 copper-nickel alloy or a Monel-400 copper-nickel alloy (Monel-400 is a trademark brand for an alloy of about 63% nickel and 31% copper).
- a UNS C71500 copper-nickel alloy or a Monel-400 copper-nickel alloy (Monel-400 is a trademark brand for an alloy of about 63% nickel and 31% copper).
- Each stave 30 preferably may be curved about its horizontal axis and/or about its vertical axis to match the internal profile of the furnace or area in which they will be used.
- Each stave 30 preferably comprises a plurality of stave ribs 32 and a stave socle 33 to support stave 30 in a standing position which may be a fully upright 90 degrees as shown, or a tilted or slanted position (not shown).
- Each stave rib 32 preferably defines a generally arcuate top rib section 34 and a generally arcuate bottom rib section 35.
- Stave 30 preferably defines a plurality stave channels 37 between each successive pair of stave ribs 32.
- each stave channel 37 is generally "C-shaped” or “U-shaped” and includes a generally planar stave channel wall 38, although stave channel wall 38 may also be curved or contoured along its vertical and/or horizontal axes, toothed, etc., to be complementary with the front face 31 of brick 18 if such front face 31 has a shape other than the planar shape depicted herein, which may depend upon the application.
- Each stave channel 37 also preferably includes a generally arcuate upper channel section 39 and a generally arcuate lower channel section 40, all as defined by stave 30 and a successive pair of stave ribs 32.
- the shapes, geometries and/or cross-sections of one or more of the stave ribs 32, top rib sections 34, bottom rib sections 35, stave channels 37, stave channel walls 38, upper channel sections 39 and lower channel sections 40 preferably may be modified or take other forms such as being contoured, angular, rectilinear, polygonal, geared, toothed, symmetrical, asymmetrical or irregular instead the shapes of the preferred embodiments thereof as shown in the drawings hereof without departing from the scope of the invention hereof.
- stave bricks 18 of the present invention may be slid into stave channels 37 from the sides 45 of stave 30 when space permits, stave bricks 18 may also preferably and advantageously be inserted into the front face 47 of staves 30.
- each stave channel 37 may be filled with stave bricks 18 by rotating or tilting each brick 18 in a first direction 46 where the bottom portion of brick 18 moves away from stave 30 preferably (1) about an axis substantially parallel a plane of the stave or (2) to allow nose 23 to be inserted into stave channel 37 and into concave, arcuate upper channel section 39, after which brick 18 is rotated in a second direction 48 generally such that the bottom of brick 18 moves toward stave 30 until (i) nose 23 is disposed in-whole or in-part within concave, arcuate upper channel section 39 with or without the perimeter of nose 23 being in partial or complete contact with upper channel section 39, (ii) front face 31 of brick 18 is disposed substantially near and/or adjacent to channel wall 38 with or without the front face 31 being in partial or complete contact with channel wall 38, (iii) arcuate seat 25 is disposed in-whole or in-part within arcuate lower channel section 40 with or without the perimeter of seat 25 being in partial or complete contact with
- each of the bricks 18 is prevented from being moved linearly out of stave channel 37 tlirough the opening in the front face 47 of stave 30 without each brick 18 being rotated such that the bottom thereof is rotated away from the front face 47 of stave 30.
- stave/refractory brick construction 28 of the present invention as shown in FIGS. 3-7 and 10 may be employed with or without mortar between adjacent stave bricks 18.
- FIG. 8 illustrates another preferred embodiment of a stave/brick construction 90 of the present invention which is the same as stave/ brick construction 28 of FIGS. 4-7 except that it employs at least two different sizes of stave bricks 92 and 94, respectively, to form an uneven front face 96.
- bricks 92 of the stave/brick construction 90 have a greater overall depth "eel” than the depth "ce2" of bricks 94.
- This staggered construction resulting from the different depths of stave bricks 92 and 94, respectively, may preferably be used in accretion zones or other desirable zones of the furnace where the uneven front face 96 would be more effective at holding an accretion or buildup of material to further protect the bricks 92 and 94 from thermal and/or mechanical damage.
- FIG. 9 illustrates the use of conventional stave/brick constructions 58 within a furnace 49.
- staves/coolers such as the flat/planar upper and lower staves 52 and 53, respectively
- pre-installed bricks 54 arranged within furnace shell 51 such staves 52 and 53 are installed in the furnace 49 such that ram gaps 56 exist in between adjacent pairs of upper staves 52 and such that ram gaps 57 exist in between adjacent pairs of lower staves 53, both to allow for construction allowance.
- These ram gaps 56 and 57 must be used to allow for construction deviation.
- Such ram gaps 56 and 57 are typically rammed with refractory material (not shown) to close such gaps 56 and 57 between the adjacent stave/brick constructions 58.
- Such material filled gaps 56 and 57 typically are weak points in such conventional furnace linings using stave/brick constructions 58.
- the rammed gaps 56 and 57 erode prematurely and furnace gases track between the stave/brick constructions 58.
- the furnace can be bricked continuously around its circumference to eliminate conventional rammed gaps with bricks 18. As shown in FIG.
- the gaps 42 between staves 30 are covered by one or more of bricks 18 of the present invention, eliminating the need for ramming filling material into such gaps 42.
- the integrity and life of the furnace and/or furnace lining is increased.
- Another problem associated with the conventional stave/brick constructions 58 having pre-installed bricks 54, as shown in FIG. 9, is that because such conventional stave/brick constructions 58 are not continuously bricked around the circumference of furnace 49, edges 55 of numerous of the bricks 54 protrude into the interior of furnace 49 and are thus exposed to any matter falling through the furnace 49. Such protruding edges 55 tend to wear faster and/or are susceptible to being hit by falling matter, causing such bricks 54 with protruding edges 55 to break off into the furnace 49 and expose the staves 52 and 53.
- the stave/brick constructions 28 of the present invention allow the furnace to be bricked continuously around its circumference thereby eliminating any such protruding brick edges 55, as shown in FIG. 10.
- the occurrences of (i) bricks 18 being pulled or knocked out of staves 30 and (ii) of staves 30 being directly exposed to the intense heat of the furnace are both significantly reduced by the stave/brick construction 28 of the present invention.
- Such characteristics make the stave/brick construction 28 of the present invention well-suited for use in the stack of blast furnaces.
- a plurality of pin mounting cylinders 43 are preferably formed on the back side of each stave 30 for mounting pins 41 used to handle each stave 30, and/or to secure and/or mount each stave 30 within a furnace.
- Each of the pins 41 preferably defines a threaded or unthreaded thermocouple mounting hole (not shown) allowing one or more thermocouples to be easily installed at various locations on each stave 30.
- FIGS. 3-8 and 10 While the preferred embodiment of a stave/refractory brick construction 28 of the present invention shown in FIGS. 3-8 and 10, includes a preferred embodiment of a furnace cooler or stave 30, the teachings of the present invention are also applicable to a frame/brick construction where such frame (not shown) is not limited to a furnace cooler or stave 30, but is a frame for providing a standing or other supported vertical or slanted wall of bricks, whether or not refractory bricks, for applications including, but not limited to, furnace applications.
- FIGS 11-12 illustrate another preferred embodiment of a stave/brick construction 59 of the present invention comprising stave 60 and alternating shallow and deep dovetail bricks 68 and 69, respectively, including top line stave brick 67 which preferably has the same depth as a long brick 69 and an exposed face 75 of greater height than the exposed faces 76 of the other shallow and deep dovetail bricks 68 and 69.
- both shallow and deep dovetail bricks 68 and 69 have upper and lower dovetail or oblique sections 73 and 74, respectively.
- each of the bricks 67, 68 and 69 defines two brick corners 71 while deep bricks 69 define two concave brick vertexes 70 that match up with the brick corners 71 of shallow bricks 68 upon completion of the stave/brick construction 59 of the present invention.
- Stave 60 preferably comprises a plurality of stave ribs 64 and a stave socle (not shown) to support stave 60 in a standing position which may be a fully upright 90 degrees, or a tilted or slanted position.
- Each stave rib 64 preferably defines generally angular upper and lower rib edges 65 and 66, respectively.
- Stave 60 preferably defines a plurality stave channels 61 between each successive pair of stave ribs 64.
- each stave channel 61 comprises a generally planar stave channel wall 77, although stave channel wall 77 may also be curved or contoured along its vertical and/or horizontal axes, toothed, etc., to be complementary with the front faces 78 of the deep dovetail bricks 69 if such front face 78 has a shape other than the planar shape depicted herein, which may depend upon the application.
- Each stave channel 61 also preferably includes a generally dovetail-shaped upper channel section 62 and a generally dovetail-shaped lower channel section 63, all as defined by stave 60 and a successive pair of stave ribs 64.
- the shapes, geometries and/or cross-sections of one or more of the stave ribs 64, upper and lower rib edges 65 and 66, stave channels 61, stave channel walls 77, upper channel sections 62, lower channel sections 63, brick vertexes 70 and brick edges 71, upper and lower dovetail sections 73 and 74, exposed faces 75 and 76 and front faces 78 preferably may be modified or take other forms such as being contoured, angular, rectilinear, polygonal, geared, toothed, symmetrical, asymmetrical or irregular instead the shapes of the preferred embodiments thereof as shown in the drawings hereof with out departing from the scope of the present invention.
- stave/brick construction 59 of the present invention in FIG. 12 shows that every other one 79 of stave ribs 64 is preferably shortened by less than half the thickness (i.e., width) of bricks 67, 68 and 69, that is by: ((brick thickness - designed gap length between the staves or coolers)/2) + 1/4" for construction deviation.
- An additional brick (not shown), preferably of higher thermal conductivity to promote cooling similar to that of the stave/cooler 60, would be installed in place of the missing section of stave rib 64 to fill the void 80.
- Such stave/brick construction 59 allows the bricks 67, 68 and 69 to be inserted into and/or removed from stave channels 61, after stave 60 has been installed in the furnace, by sliding such bricks into stave channels 61 via voids 80, i.e., the extra room created by shortened stave ribs 79.
- the stave/brick construction 59 may preferably employ a single brick design (not shown) or the alternating shallow and deep bricks 68 and 69, respectively, as shown in FIG. 11 wherein the dovetail sections 73 and 74 of deep bricks 69 are inserted and received into stave channels 61, each of the front faces 78 of shallow bricks 68 is disposed substantially near and/or adjacent to a respective face 81 of a stave rib 64 with or without such front face 78 being in partial or complete contact with its respective rib face 81, and each of the brick edges 71 of shallow bricks 68 is disposed substantially near and/or adjacent to a respective vertex 70 of a deep brick 69 with or without such brick edge 71 being in partial or complete contact with its respective vertex 70 of a deep brick 69. Additionally, other stave/brick constructions employing bricks of two or more different shapes with a portion of all such bricks being received in a stave channel is within the scope of the present invention.
- the stave/brick constructions of the present invention preferably also may be assembled initially by setting the bricks in a form and casting the stave around the bricks.
- the refractory wear monitoring system 100 of the present invention increases the accuracy of measurement of refractory and stave thickness and wear and provides an early warning system for refractory wear.
- the refractory wear monitoring system 100 of the present invention is preferably employed with conventional stave/brick systems, drilled and plugged stave/brick systems and/or the improved double-locking stave brick systems disclosed herein.
- FIG. 13 depicts the placement of the wear monitor system 100 of the present invention in a stave/brick construction 28 at a critical wear region where there is a desire to monitor/determine the refractory wall thickness and condition.
- Holes are cut into the refractory at 111 and 115 between refractory bricks 18 to allow the insertion of the wear monitors 101 and thermocouples 105 into the cut refractory wall.
- Installing a combination of wear monitors 101 and thermocouples 105 into the stave/brick construction 28 allows for the continuous monitoring of process information such as refractory depth and temperature to optimize furnace and refractory performance, establish stable accretions and maximize furnace life.
- process information such as refractory depth and temperature
- furnace and refractory performance establish stable accretions and maximize furnace life.
- Using the wear monitoring system and improved stave/brick construction 28 of the present invention it is possible to identify if and where refractory is wearing out and replace it during a short furnace outage without removing the staves 30.
- FIG. 14 depicts the placement of the refractory wear monitors 101 and the thermocouples 105 in the ram gap joint 42 disposed between staves 30 where the holes for placing the wear monitor 101 and the thermocouple 105 have been fashioned.
- the holes may be made by drilling or defined by the refractory material used to fill ram gaps 42.
- the cement of a similar type to that of the bricks 18 may be used to fill in the spaces and secure the placement of the wear monitor 101 and the thermocouple 105.
- FIG. 5 is a side perspective view of a preferred embodiment of a stave/brick construction 28 for use with the wear monitoring system 100 of the present invention as shown in FIGS. 13-16.
- the refractory wear monitoring system 100 of the present invention is directed to a preferred apparatus for measuring the thickness of refractory wall in a blast furnace or other type of metallurgical apparatus and, more specifically, to measuring the thickness of a refractory wall of a stave/brick construction 28.
- the preferred wear monitors 101 are designed to used with time-domain reflectometry techniques and have two ends, a refractory end 101R and a system end 101 S.
- the system end 101 S may be operatively connected to a junction box or may be connected directly to the electrical connector means by which the device is connected to an electronic monitor instrument.
- these specific known critical wear regions or the critical wear zones are the likely points were refractory wear will predominantly take place.
- the refractory ends 10 IS of the wear monitors 101 the monitoring system 100 also erode at substantially the same rate as the refractory and/or refractory bricks 18.
- the loss in length of the monitoring device 101 is substantially equal to the loss of the refractory because the original thickness of the refractory and the position of the refractory ends 10 IS of the wear monitors 101 can be determined at any time from the length of the monitoring device displayed on the analysis equipment used in association with the present invention. This calculation is accomplished by subtracting the displayed length of the monitoring device 101 from the original displayed length thereof, determined along with a suitable calibration of the recording instrument and in turn subtracting the difference determined from the known thickness of the original refractory. Alternately stated, the erosion or loss in thickness of the refractory is equal to the loss of length of the embedded wear monitor 101.
- the included thermocouple devices 105 may also be used to monitor the temperature at such measured locations on an ongoing basis.
- a third preferred aspect of the present invention is using a laser or optical scanner to produce a profile of the furnace refractory interior surface for determination of any significant changes that indicate refractory loss that can take place within critical and/or non-critical wear regions of the furnace.
- the laser or optical detector/scanner 120 of the present invention preferably comprises a laser light emitter and a receiver to scan the interior where the profile measurements are detected through triangulation methods.
- the refractory wear monitoring system 100 of the present invention preferably comprises wear monitors 101 comprising a central metallic conductor 102 and an outer metallic sheath 103 separated from the conductor by a fine close-packed insulating 104 material having a desirable dielectric constant.
- the wear monitors 101 each having two ends, a refractory end 101R and a system end 101S.
- the refractory brick 18 has a furnace side 126 and a stave side 129.
- the refractory end 101R of the wear monitor traverses the refractory to furnace side surface 126 coming even with the surface and the wear monitor portion.
- the wear monitor system end 10 IS may be lead to a junction box and be connected to an electrical connector means attached thereto or may be connected directly to the electrical connector means by which the device is connected to an electronic instrument which uses time-domain reflectometry
- the conductor and sheath are made from any material which will be electrically conductive and withstand the hostile environment of the interior of a furnace or other metallurgical apparatus.
- Appropriate materials for the conductor 102 include stainless steel, molybdenum, iron, platinum, tungsten, and nickel-base alloys.
- a preferred construction is to use molybdenum for the conductor 102 and stainless steel for the sheath 103.
- the system end 101S of the wear monitor 101 is designed to pass through staves 30 as shown in FIG. 10 wherein each of the monitoring pins 41 may preferably define a threaded or unthreaded hole or conduit for receiving a wear monitor 101 and/or thermocouple 105 according to the present invention.
- the wear monitor refractory ends 101R pass through the staves 30, bricks 18 and on through the shell of the furnace.
- Each thennocouple 105 will also have a refractory end 105R and a system end 105S.
- the thermocouples 105 will not traverse the refractory bricks 18 as the wear probes 101R do, but will stop at a point determined to be an imminent fail location.
- thermocouples 105 When the bricks 18 wear to the point of the irnminent fail location, the thermocouples 105 will begin to wear. At that point, there can be a fail-safe system warning of imminent failure at that location. Both system ends of the wear monitors 101 S and the thermocouple 105 S will extend past the staves 30 and traverse the furnace shell.
- a closure plate 107 is set around the ends 105S of thermocouple 105 and 10 IS of wear monitor 101 that project through the furnace shell 51.
- the thermocouples 105 preferably may be of type B, S, R or K or similar capable type that may be hereinafter invented for recording high temperatures with reasonable accuracy and reliability.
- the closure plate 107 can be made of any suitable material having the appropriate temperature resistant and wear qualities for sealing or supporting the furnace vessel shell. It is also foreseeable to have a refractory bricks having integrated wear monitors and/or thermocouples that would be placed along critical wear regions in an alternating position at specific distances to further extend the coverage area of the wear monitor system 100
- Data transmitting cables are then attached to the thermocouple 105S and the wear monitor 101S system ends. These data transmitting cables may lead to the electronic data relay circuit junction boxes. These junction boxes are assigned according to the probe and thermocouple location. This enables signals to be transmitted and data to be read by computer processing equipment according to the location of the specific probes. The data readings may be made during work outages or data can be continuously transmitted "real time" during furnace operation. The signals may be transmitted directly to a local testing analysis computer or may be transmitted via network connections to an off-site location or the data feed could be transmitted to both a local analysis computer and via network to an off-site location for reading and analysis.
- thermocouple and wear monitor This data provided from the thermocouple and wear monitor is processed by computers for temperature status and remaining wall thickness and analyzed by operators and engineers to determine the immediate effect of the practices to the staves 30 and refractory bricks 18.
- This analysis can be done both on-site and/or remotely as the data can be transmitted through network connections, therefore off-site engineers can interact with the on-site engineers to determine best operating temperatures/conditions for the furnace.
- the engineers and operators can then adjust furnace variables to provide optimum furnace performance and ascertain the available time remaining before necessary furnace shutdown to facilitate refractory replacement and thereby improve efficiency while preventing catastrophic failure and/or furnace blowout.
- FIG. 17 shows a further preferred embodiment of the present invention which integrates a laser scanning and mapping system 117 to automatically scan and map the interior of the furnace and track the internal condition of staves 30 and refractory bricks 18.
- the mapping system 117 uses energy waves such as laser light waves 121 from a emitter/receiver unit 120 to obtain the distance between the refractory wall and the wave generator based on the time duration or the phase difference of waves from the emission by the emitter/receiver 120 till the return of the light waves 121 to the emitter/receiver 120 after being reflected by the faces of refractory wall and/or bricks 18, and based on changes of this distance, calculates the position and the amount of corrosion and the thickness of the refractory wall and/or bricks 18.
- This scan may take place between load periods and/or at maintenance times.
- an original time point TO reference mapping scan is taken to serve as a baseline to determine changes over time to the refractory surface.
- a point TO reference time refractory layer mapping analysis would preferably be taken for later comparison at later scan times and held in the database memory.
- the scans performed at later points will be cross referenced to analyze changes in the surface structure as a direct comparison.
- the point TO mapping scans are not required to be taken during a maintenance shutdown of the furnace, but for optimal comparison to later point mapping scans, a full inspection and measurement analysis could preferably be taken to determine refractory thickness and condition. This may be done at the time of the installation of the refractory bricks 18 and staves 30. Additional preferred embodiments of the laser mapping scan system 100 will map the interior of the furnace without the necessity of taking a baseline TO comparative reading at the refractory installation point.
- the system of the present invention preferably takes into account various data factors provided including vessel tilt, accretion density, slag weight, charge weight and scans the interior generating a map providing a quantitative and qualitative assessment of vessel lining thickness.
- the emitter/receiver 120 is connected to a computer and the data from the laser scan will be processed by a computer.
- the emitter/receiver 120 can be directly attached to the computer by way of data transmitting cables or the laser scanning device may be attached to wireless transmitter or have a self contained wireless transmitter and relay the data to the computer database by way of wireless interface with the computer.
- the data transmitted to the database may be integrated in a single display with the data from the refractory wear monitors 101 and the thermocouples 105 creating a whole system map with a three dimensional visual presentation.
- the data may be displayed independently in various formats and display views as needed for detailed and/or customized analysis.
- the emitter/receiver 120 can be provided either on a fixed platform at an area having access to the interior of the furnace or as a mobile platform.
- the laser system 1 17 may be mounted in a cooled protective enclosure.
- the door can be actuated to expose the scanning laser optics.
- the cooled enclosure may be cooled with any coolant appropriate for the function and capable of protecting the laser optic emitter/receiver 120, including water.
- the door can be actuated with any known means that would be appropriate for high temperature conditions, including pneumatic or hydraulic actuation means.
- the laser emitter/receiver 120 will broadcast energy waves into the furnace and read the reflected waves.
- the frequency is not refracted by the heat energy and while some dispersion may be caused by matter within the furnace, the scanning frequency and software algorithms compensate for any deflection that may result in stray data points and the resulting data can be displayed as a map indicting the distances of the various interior surfaces of the refractory walls and/or bricks 18 that can be calculated by the software to determine refractory thickness.
- a further embodiment of the laser optic scanner can be introduced into the interior 49 of the furnace via a lance tip. Wherein the laser optic scanner is provided within the shielded protected receptacle on a lance tip, the lance is cooled with any coolant appropriate, including water and projected into the furnace to scan the interior surfaces of the refractory and/or bricks 18. It is also foreseen that a further embodiment of the laser optic scanner provides that the laser optic scanner can function as a mobile unit and be set in at any opening to the furnace that may provide ease of scan.
- a high speed 3-D scanner coupled with laser-based localization system integrates a localization identification system that identifies specific points to work for position identification.
- the scan data can then be broadcast with via wired or wireless networks to a computer that will generate a map profile of the vessel.
- Such profile can be used in combination with the present invention's system of thermocouples 65 and wear monitors 61 to analyze wear points in the furnace to detect loss of refractory inside or outside of critical wear regions of the furnace to an accuracy of about 6mm.
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Abstract
L'invention concerne une construction en douve et briques comprenant : une douve ayant une pluralité de nervures et une pluralité de rainures, une face avant de la douve définissant une première ouverture débouchant dans chacune des rainures ; une pluralité de briques, chaque brique pouvant être emboîtée dans l'une de la pluralité de rainures en passant par une première ouverture pour atteindre une position, en tournant la brique partiellement disposée dans cette rainure de sorte qu'une ou plusieurs parties de la brique coopèrent au moins partiellement avec une ou plusieurs surfaces de cette rainure et/ou d'une première nervure de la pluralité de nervures de sorte que la brique soit verrouillée et ne puisse pas être dégagée de la première rainure en passant à travers l'ouverture par un mouvement linéaire sans avoir initialement été tournée ; et un ou plusieurs témoins d'usure et/ou thermocouples, chaque témoin d'usure et thermocouple étant disposé à travers la douve et/ou une ou plusieurs des briques, ou disposé dans une position adjacente à cette douve ou à une ou plusieurs de ces briques.
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Cited By (5)
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WO2014121213A2 (fr) * | 2013-02-01 | 2014-08-07 | Berry Metal Company | Douve ayant un collecteur externe |
WO2017109282A1 (fr) * | 2015-12-21 | 2017-06-29 | Outotec (Finland) Oy | Procédé et système pour le suivi de l'état d'un élément d'usure, utilisation du procédé et du système et four de frittage sur bande |
WO2019092241A1 (fr) | 2017-11-13 | 2019-05-16 | Paul Wurth S.A. | Surveillance de l'état d'un four à cuve |
CN113195993A (zh) * | 2018-11-29 | 2021-07-30 | 圣戈本陶瓷及塑料股份有限公司 | 耐火制品 |
US12071675B2 (en) | 2017-11-13 | 2024-08-27 | Paul Wurth S.A. | Shaft furnace condition monitoring |
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KR101870708B1 (ko) | 2016-12-05 | 2018-07-19 | 주식회사 포스코 | 블록 구조체, 용기 및 블록 구조체의 시공 방법 |
KR102083533B1 (ko) * | 2017-11-21 | 2020-03-02 | 주식회사 포스코 | 처리 장치 |
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WO2014121213A2 (fr) * | 2013-02-01 | 2014-08-07 | Berry Metal Company | Douve ayant un collecteur externe |
WO2014121213A3 (fr) * | 2013-02-01 | 2014-10-23 | Berry Metal Company | Douve ayant un collecteur externe |
US10222124B2 (en) | 2013-02-01 | 2019-03-05 | Berry Metal Company | Stave with external manifold |
WO2017109282A1 (fr) * | 2015-12-21 | 2017-06-29 | Outotec (Finland) Oy | Procédé et système pour le suivi de l'état d'un élément d'usure, utilisation du procédé et du système et four de frittage sur bande |
WO2019092241A1 (fr) | 2017-11-13 | 2019-05-16 | Paul Wurth S.A. | Surveillance de l'état d'un four à cuve |
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US12071675B2 (en) | 2017-11-13 | 2024-08-27 | Paul Wurth S.A. | Shaft furnace condition monitoring |
CN113195993A (zh) * | 2018-11-29 | 2021-07-30 | 圣戈本陶瓷及塑料股份有限公司 | 耐火制品 |
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