WO2024086732A1 - Dispositif et système d'ancrage réfractaire - Google Patents

Dispositif et système d'ancrage réfractaire Download PDF

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Publication number
WO2024086732A1
WO2024086732A1 PCT/US2023/077324 US2023077324W WO2024086732A1 WO 2024086732 A1 WO2024086732 A1 WO 2024086732A1 US 2023077324 W US2023077324 W US 2023077324W WO 2024086732 A1 WO2024086732 A1 WO 2024086732A1
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WIPO (PCT)
Prior art keywords
main body
segments
refractory
segment
anchoring device
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PCT/US2023/077324
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English (en)
Inventor
Eduardo Fernando D'Oracio De Almeida
Anthony Stephen Harris
Original Assignee
Brand Shared Services, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Priority claimed from US17/968,934 external-priority patent/US20230041165A1/en
Application filed by Brand Shared Services, Llc filed Critical Brand Shared Services, Llc
Publication of WO2024086732A1 publication Critical patent/WO2024086732A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23M—CASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR
    • F23M5/00—Casings; Linings; Walls
    • F23M5/04—Supports for linings
    • 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
    • F27D1/14—Supports for linings
    • F27D1/141—Anchors therefor

Definitions

  • the present invention relates generally to the field of refractory linings for high-temperature vessels used in industrial and chemical processes, and more particularly to anchor systems for holding refractory materials in place in high- temperature and abrasive environments.
  • Thermal-process vessels used in oil refineries and other petrochemical and chemical process facilities have highly abrasive and high-temperature environments.
  • a refractory material such as a thin layer of concrete.
  • anchoring devices and systems have been developed.
  • Hex thin-layer abrasion-resistant refractory concrete anchoring system
  • Hex includes a series of steel strips that are interlocked (i.e., “clinched” together by a tab-and-slot arrangement) to form a sheet or mat of hexagonal cells in a honeycomb- patterned array or grid.
  • the hex sheets are installed by fitting (bending/shaping and cutting/sizing) them to whatever vessel shape and size is to be lined, and then welding them in place by a large number of welds to create a strong attachment to the underlying vessel shell.
  • mixed refractory concrete is then rammed, beaten, or packed into the hex cells.
  • the refractory concrete and hex sheet together form a barrier system that protects the underlying vessel shell from heat, abrasion, and chemical attack.
  • D-BAR anchors e.g., U.S. Patent No. 6,393,789
  • C-BAR anchors C-BAR anchors
  • G3 anchors Some of these are provided in sheet form and thus must by bent and cut to fit the individual vessel in the same manner as the HEXMESH sheets. And some of these include multiple parts that are interlocked together with a clinching system in the same manner as the HEXMESH sheets. As such, these other refractory anchoring devices and systems include some or all of the same drawbacks.
  • the present invention relates to refractory anchoring devices having unenclosed semi-hexagonal cell openings.
  • the refractory anchoring devices each include a main body and a mounting feature for mounting to a thermal vessel.
  • the main body has the shape of two end-to-end Y’s forming a central segment, two branch segments extending at an obtuse angle from each of the two ends of the central segment, and an extension segment extending at an obtuse angle from each of the four branch segments, to collectively form four unenclosed cell openings that are each semi-hexagonal in shape.
  • Some embodiments include four reinforcement segments with each one extending into a respective cell opening, four voids with each one extending through respective adjacent branch and extension segments, an underbody gap formed under the central segment for refractory interlinking between cell openings, a single stud-welding cylinder for the mounting feature, and/or a collar-and- stud connection between the anchor main body and a stud-welding stud of the mounting feature.
  • Another aspect of the invention relates to refractory anchoring systems that include an array of refractory anchoring devices having unenclosed semi-hexagonal cell openings.
  • the refractory anchoring devices are arranged in the refractory anchoring systems so that the unenclosed semi-hexagonal cell openings of adjacent ones of the anchoring devices cooperate to form substantially hexagonal cells and provide flow passageways for the refractory to interconnect the cells.
  • refractory lining methods that use an array of refractory anchoring devices having unenclosed semi-hexagonal cell openings.
  • the method includes mounting the refractory anchoring devices in an arrangement to form refractory anchoring systems with the unenclosed semi-hexagonal cell openings of adjacent ones of the anchoring devices cooperating to form substantially hexagonal cells and provide flow passageways for the refractory to interconnect the cells.
  • the refractory anchoring devices include a single stud-welding stud for a mounting feature and the mounting process includes stud-welding the anchor devices in place (for example using BRANDTECH precision welding equipment and processes).
  • Figure 1 is a perspective view of a refractory anchor according to a first example embodiment of the invention.
  • Figure 2 is another perspective view of the refractory anchor of Figure 1 .
  • Figure 3 is a top view of the refractory anchor of Figure 1 .
  • Figure 4 is a bottom view of the refractory anchor of Figure 1 .
  • Figure 5 is a side view of the refractory anchor of Figure 1 .
  • Figure 5A shows the refractory anchor of Figure 5 with a welding stud shown in cross section.
  • Figure 6 is an end view of the refractory anchor of Figure 1 .
  • Figure 7 is a perspective view of a refractory anchor according to a second example embodiment of the invention.
  • Figure 8 is another perspective view of the refractory anchor of Figure 7.
  • Figure 9 is another perspective view of the refractory anchor of Figure 7.
  • Figure 10 is a top view of the refractory anchor of Figure 7.
  • Figure 11 is an end view of the refractory anchor of Figure 10.
  • Figure 12 is a side view of the refractory anchor of Figure 10.
  • Figure 13 is a top view of a first anchoring system of the refractory anchors of Figure 1 .
  • Figure 13A is a perspective view of the first anchoring system of Figure 13 showing the installed refractory, with portions removed to reveal the underlying anchors, forming generally hexagonal, interlinked cells.
  • Figure 14 is a top view of a second anchoring system of the refractory anchors of Figure 1 and the refractory anchors of Figure 7.
  • Figure 15 is a top view of a third anchoring system of the anchors of Figure 1 and modified/alternative refractory anchors according to a third example embodiment.
  • Figure 16 is a top view of a fourth anchoring system of modified/alternative refractory anchors according to a fourth example embodiment.
  • Figure 17 is a top view of a fifth anchoring system of modified/alternative refractory anchors according to a fifth example embodiment.
  • Figure 18 is a perspective view of a portion of a refractory anchor according to a sixth example embodiment.
  • Figure 19 is a top view of the refractory anchor portion of Figure 18.
  • Figure 20 is a perspective view of a portion of a refractory anchor according to a seventh example embodiment.
  • Figure 21 is a perspective view of a refractory anchor according to an eighth example embodiment.
  • Figure 22 is a side view of a main body of the refractory anchor of Figure
  • Figure 23 is a top view of the refractory anchor main body of Figure 22.
  • Figure 24 is a bottom view of the refractory anchor main body of Figure
  • Figure 25 is a perspective view of a stud of the refractory anchor of Figure 21.
  • Figure 26 is a side view of the refractory anchor stud of Figure 25.
  • Figure 27 is a cross-sectional view of the refractory anchor taken at line 27-27 of Figure 21.
  • the present invention relates to an anchoring device, system, and method for a refractory material for together forming a protective barrier system for a thermal vessel.
  • the anchoring device, system, and method can be used for protecting thermal vessels such as high-temperature cyclone separators (e.g., fluid catalytic crackers aka FCCs), burners, furnaces, columns, and tanks, piping for these, and other high-temperature industrial-process containers. These thermal vessels operate at high temperatures of typically about 250 C to about 1800 C.
  • the anchoring device, system, and method can be used for protecting such thermal vessels in oil refineries, other petrochemical-process facilities, chemical-process facilities, chemical- manufacturing plants, cement plants, fertilizer plants, steel mills, pulp-and-paper plants, power-generating plants, and other facilities and industries using such high- temperature vessels.
  • the anchoring device, system, and method can be used for anchoring refractory materials including concrete, fibers, plastics, ceramics, and/or other conventional refractories, typically applied in a viscous state and cured on site, but in some embodiments precast or otherwise pre-formed.
  • Figures 1-6 show a thin-layer abrasion- resistant refractory anchoring device 10 according to a first example embodiment of the invention.
  • the anchor 10 includes a main body 12 having the shape of two “Y”s arranged end-to-end (and thereby defining two side/central semi-hexagonal (trapezoidal) openings and two end triangular openings) and a mounting element or feature 14 for mounting the main body 12 to the thermal vessel (not shown) to be protected.
  • the main body 12 includes a central segment 16 (i.e., the aligned and continuous base legs of the two end-to-end “Y”s) and four branch segments 18 extending from the central segment 14 (i.e., the two pairs of splayed upper legs of the two end-to-end “Y”s) with a first pair of the branch segments 18 extending from a first part of the central segment 14 and with a second opposite pair of the branch segments 18 extending from a second part of the central segment 14 that is spaced apart from the first part.
  • the two branch segment pairs 18 extend from opposite outer end portions 20 of the central segment 16.
  • the branch segments extend from the central segment before its end edges (with the central segment extending into the end openings) or are otherwise configured.
  • the four branch segments 18 are each angled with respect to the central segment 14 at an obtuse angle to form four unenclosed cell openings (e.g., notches or recesses) 22 between them.
  • each of the four branch segments 18 is arranged at an obtuse angle a of about 120 degrees from the central segment 14 in a substantially symmetrical configuration, which leaves an obtuse angle [3 of about 120 degrees between the two branch segments 18 at each end portion 20 of the central segment 14.
  • the branch segments extend from the central segment all at the same larger or smaller obtuse angle, at two to four different angles from each other, or in another configuration.
  • the main body 12 of typical embodiments further includes one or more extension segments 24 extending from one or more of the branch segments 18.
  • the main body 12 includes four extension segments 24 with each one extending from a respective one of the four branch segments 18.
  • the extension segments 24 extend from outer end portions 26 of the respective branch segments 18.
  • the extension segments extend from the branch segments before their end edges (with the branch segments extending beyond where the extension segments extend from) or are otherwise configured.
  • the main body does not include any extension segments.
  • the four extension segments 24 are each angled relative to their respective branch segments 18 at an obtuse angle to define portions of the two opposite end openings 22.
  • each of the four extension segments 24 is arranged at an obtuse angle 0 of about 120 degrees from the respective branch segment 18 in a substantially symmetrical configuration, leaving the extension segments 24 substantially parallel with the central segment 16.
  • each pair of the branch segments 18 and the central segment 16 are symmetrically arranged, with each one of these three segments at 120 degrees from the other two of these three segments.
  • the extension segments extend from the branch segments all at the same larger or smaller obtuse angle, at two to four different angles from each other, or in another configuration.
  • all four of the openings 22 are semi-hexagonal (the extension segments making the triangular end openings into semi-hexagonal openings).
  • the two opposite end semi-hexagonal openings 22 are formed by one end pair of the branch segments 18 (defining two adjacent full-length sides of a hexagon) and by one end pair of the extension segments 24 (defining two opposite/facing half-length sides of a hexagon), as shown in Figures 3 and 6.
  • the two opposite central semi-hexagonal openings 22 are formed by the central segment 16 (defining one full-length side of a hexagon) and two of the branch segments 18 (one of each end pair; each one defining one full-length side of a hexagon), as shown in Figures 3 and 5.
  • the end semi- hexagonal openings 22 and the central semi-hexagonal openings 22 are rotationally shifted by about 60 degrees with respect to each other so that they are arranged together in a tessellated fashion.
  • each of the branch segments 18 typically has a length that is substantially the same as that of the central segment 16 (with all of the branch segments 18 having the same length), and each of the extension segments 24 typically has a length that is about half (or less than about half) that of the central and branch segments 16 and 18 (with all of the extension segments 24 having the same length).
  • each of the unenclosed cell openings 22 defines a regular (equilateral) semi-hexagonal shape of the same size/area, so that a number of the anchors 10 can be arranged together with any one of the four cells/openings 22 of one anchor cooperating with any one of the four cells/openings of an adjacent anchor to form a substantially hexagonal cell, thereby reducing the likelihood of biscuiting.
  • the length of the central and branch segments 16 and 18 (and twice the length of the extension segments 24) is about 20mm to about 30mm (e.g., about 25mm), with the openings 22 thus being about 50mm to about 60mm (e.g., about 55mm) across (e.g., between the extension segments 24 of each end pair).
  • the central, branch, and/or extension segments all have a longer or shorter length, have different lengths from each other, or are provided with other lengths as may be desired.
  • the extension segments are shorter than one-half the length of the central and/or branch segments, so that two anchoring devices can be arranged end-to-end adjacently but spaced apart in an anchoring system (in the manner shown in Figure 13, except with shorter extension segments), and the adjacent end openings of the two anchors cooperate to form a regular hexagonal cell (though not fully enclosed because of the end-to-end spacing between the anchors), for example as shown in Figure 15.
  • only one of the branch segments at each end has an extension segment extending from it (so there are two extension segments, one at each end of the anchor), so that two anchoring devices can be arranged side-to-side immediately adjacently (e.g., with nominal spacing sufficient to avoid contacting during thermal expansion and contraction during use) in an anchoring system (in the manner shown in Figure 13, except with no side-to-side spacing), with each extension segment positioned at a branch segment of the adjacent anchor without an extension segment (to fill the position where an extension segment was not included in that anchor), and the adjacent central/side openings of the two anchors cooperate to form a regular hexagonal cell (with nominal spacing sufficient to avoid contacting during thermal expansion and contraction during use), for example as shown in Figures 16 and 17.
  • the main body 12 of typical embodiments further includes one or more reinforcement segments 28 extending into one or more of the four openings 22.
  • the main body 12 includes four reinforcement segments 28 with each one extending into a respective one of the four openings 22 so that each of the four openings 22 has a respective reinforcement segment 28 extending into it.
  • the reinforcement segments 28 each are generally linear and have a length of about 10mm to about 20mm (e.g., 15mm), though they can be provided in other regular or irregular shapes, sizes, and/or configurations, as may be desired for an application.
  • the reinforcement segments 28 are thus in addition to the symmetrical semi-hex arrangement of the two branch segments 18 and the two extension segments 24 at each end of the anchor, and do not define any portion of the semi-hex openings 22.
  • the reinforcement segments 28 provide additional contact surface area for engaging and securing the refractory in place, and they protrude into the unenclosed cell openings 22 to reduce the unobstructed distance across the openings 22, thereby better securing the refractory in the cells and helping reduce the likely incidence of biscuiting of the refractory.
  • the reinforcement segments 28 are each typically non-perpendicularly angled from the branch segment 18 they extend from and non-parallel to the adjacent branch segment 18 (on the same end of the same anchor 10, with these two branch segments together forming one Y-shaped end of the main body 12) so that they extend into the respective openings 22 in a non-symmetrical manner.
  • the non-perpendicular arrangement of the reinforcement segments 28 can be implemented, for example, by the reinforcement segments 28 being oriented/arranged at about 75 degrees relative to the branch segment 18 they extend from, and thus at an angle ⁇ t> of about 45 degrees relative to the central segment 16 (see Figure 4). This non-perpendicular arrangement of the reinforcement segments 28 avoids right angles in an effort to decrease the likelihood of biscuiting and at the same time it forms “pinch” or “catch” surfaces that help retain the refractory material in the openings 22.
  • the main body 12 includes voids 30 that provide additional contact surface area (the void-defining exposed through-surfaces 32 of the respective main-body segments) for engaging and securing the refractory in place.
  • the reinforcement segments 28 and the void through-surfaces 32 provide better retention/anchoring of the refractory material (more contact surface area)
  • the voids 30 provide for interlinking of the refractory material (which typically is flowable during installation through the voids into and extending between adjacent cells) so it is not isolated into individual cells, to provide even better retention/anchoring of the refractory material and further avoid biscuiting.
  • the reinforcement segments 28 and the voids 30 can have the same configuration (size and shape, though positive/solid and negative/void), as depicted, or they can have similar or different configurations if desired.
  • the reinforcement segments can be formed by portions of the main body that are angled from the adjacent/remainder portions of the main body to leave behind the voids in the main body that typically have substantially the same configuration as the respective reinforcement segment that vacated that void.
  • the reinforcement segments are separate pieces attached to the main body, with or without inclusion of the voids.
  • the voids 30 typically each extend continuously through adjacent ones of the branch segments 18 and the extension segments 24 that are angled relative to each other, with the lateral through-surfaces 32 of the respective main-body segments 32 (which peripherally define the voids 30) thus extending continuously through the adjacent branch and extension segments 18 and 24 and thus having two angled portions, for the refractory to flow through during installation to interconnect adjacent cells and to provide more surface-area engagement for further- enhanced securement of the refractory in place.
  • the voids extend continuously through the central and branch segments, or continuously through the central, branch, and extension segments.
  • the main body 12 typically defines underbody gaps 36 between the bottom 31 of the main body 12 (e.g., at least a portion of the central segment 16 and typically also a portion of the branch segments 18) and the vessel shell (when at least portions of the bottoms of the extension segments 24 are positioned substantially flush against the vessel shell, including direct contact and immediately adjacent such as within about 0.2 mm).
  • the bottom side (surface or edge) 31 of the main body 12 can include an elevated portion 33 (spaced from the vessel shell) at a laterally inner portion of the main body (e.g., at least a portion of the central segment 16), a base portion 35 (flush against the vessel shell) at a laterally outer portion of the main body (e.g., at least a portion of the extension segments 24), and a transition portion 34 between and connecting them (e.g., ramped (e.g., linear or curved) along at least a portion of the branch segments 18 and ramped upward toward the central segment) to form the resulting underbody gaps 36, for instance as shown in Figures 4-5.
  • an elevated portion 33 space from the vessel shell
  • a laterally inner portion of the main body e.g., at least a portion of the central segment 16
  • a base portion 35 flush against the vessel shell
  • a laterally outer portion of the main body e.g., at least a portion of the extension segments 24
  • underbody gaps 36 allow the refractory to flow (during installation) under the central segments 16 of the anchor 10 (and typically under portions of the branch segments 18) to interlink the refractory material (after curing) in the opposite side cells 22 (and also typically in the opposite end cells 22) so it is not isolated in any individual cell to provide even better retention/anchoring of the refractory material and further avoid biscuiting.
  • the main body 12 has a substantially level (e.g., planar or irregular) top side (surface or edge), with the central segment 16 (or at least a portion of it) having a height dimension He that is smaller than a height dimension HE of the extension segments 24 (or at least a portion of them), so that the underbody gaps 36 are formed under the central segment 16 but not under the extension segments 24.
  • the central segment 16 height He can be about 15mm to about 20mm (e.g., about 17mm) and the extension segments 24 height HE can be about 20mm to about 25mm (e.g., about 23mm), with the underbody gaps 36 typically having a height HG of about 4mm to about 6mm (and thus with the thin-layer refractory material typically having a thickness/height of about 20mm to about 25mm. Also, with the underside gaps 36 being laterally centrally/inwardly located, the more outerwardly located extension segments 24 (or at least portions of them) contact the vessel shell, which provides a laterally wide footprint or support base for stability of the anchor 10 in its mounting position.
  • each bottom ramped transition 34 runs from a laterally inner location 34a and outwardly (away from the central segment 16) to a laterally outer location 34b.
  • the inner locations 34a can be for example at (as depicted) or near where the branch segments 16 angle from the central segment 16 (i.e., the opposite laterally outer ends 20 of the central segment 16).
  • the outer locations 34b of the bottom ramped transitions 34 can be for example at or near (as depicted) where the extension segments 24 angle from the respective branch segments 18 (i.e., the opposite laterally outer ends 26 of the branch segments 18).
  • the outer/end locations 34b of the bottom ramped transitions 34 can be on the branch segments 16, laterally inward of the extension segments 24, so that there is relatively little/nominal lateral overlap between the underbody gaps 36 and the body voids 30 (which typically extend through the extension segments 24 and the branch segments 18).
  • at least a portion of the end location 34b of the bottom ramped transition 34 can be substantially vertically (axially) aligned with (or slightly laterally inward from, toward the central segment 16) the inner edges 32a of the void-defining through-surfaces 32, as best shown in Figures 4 and 6.
  • This arrangement provides a good underflow area (formed by the laterally inward underbody gaps 36) and a good through-flow area (formed by the laterally outward body voids 306) for the refractory (during installation) without sacrificing the structural integrity of the main body 12 (specifically, the extension segments 24 and the branch segments 18 where the voids 30 are located), for better refractory flow-through and retention in the anchor-formed cells.
  • this arrangement provides at least one flow passageway from the central segment 16, along the entire length of the respective branch segments 18, and to the respective extension segments 24, extending around the bend between the central and branch segments 16 and 18 and around the bend between the branch and extension segments 18 and 24, because the flow-through passageways (through the body 12 via the voids 30) and the flow-under passageways (under the body 12 via the gaps 36) at least nominally laterally overlap (including their ends being vertically aligned, for example adjoining and in alignment with the attached end of the respective reinforcement segment 28).
  • the body voids and the under-body gaps do not laterally overlap but they nevertheless extend between the central and branch segments, between the branch and extension segments, and along the majority of the length of these three anchor segments for better refractory flow-through and retention in the anchor-formed cells, for example continuously except where interrupted by the presence of reinforcement segments 28.
  • the mounting element or feature 14 is designed for mounting the anchor 10 to the thermal vessel (not shown) to be protected.
  • the mounting feature 14 is designed for conventional stud-welding installation methods and equipment, and it thus includes a stud (e.g., a cylinder) 38 defining a recess (e.g., a semi-spherical tap hole) 40 for receiving a metal interface/pilot element (e.g., a solid ball) 39.
  • the interface/pilot element 39 is made of a different material (relative to the stud 38) that has a lower melting point so that it melts before the stud 38 for optimal stud-welding.
  • the anchor 10 can be made of steel and the interface/pilot ball can be made of aluminum. Because of this, the interface/pilot element 39 is a separate component (relative to the stud 38 and to the rest of the anchor 10) in one-piece anchor embodiments.
  • the stud 38 and the interface/pilot element 39 can have a configuration of a conventional type as is suitable for conventional one-step stud-welding techniques, so additional details are not provided for brevity.
  • the mounting feature 14 can typically include a single stud 38 positioned at the center of the central segment 16 of the main body 12, with no other attachment of the anchor to the vessel shell (the extension segments 24 typically contact the vessel shell for stability without being attached), so that vessel expansion and contraction does not stress the weld and weaken it.
  • mounting feature is configured for manual welding or other conventional anchor attachment methods known in the art.
  • the main body 12 and the welding stud 38 are made of a single component piece of a material, such as a metal alloy (e.g., carbon steel or stainless steel such a 300 or 600 series) with a substantially uniform thickness (e.g., about 2.5mm), that is sand-cast (or otherwise fabricated by single-use molds) into a one-piece part.
  • a metal alloy e.g., carbon steel or stainless steel such a 300 or 600 series
  • a substantially uniform thickness e.g., about 2.5mm
  • the anchors 10 are modular and individually installed so that the effects of vessel expansion and contraction are minimized to help reduce the risk of biscuiting.
  • the anchor can be made of other materials and in multiple parts assembled together, or by other fabrication techniques such as other types of casting or forging, as may be desired.
  • the anchor 110 is a half-unit version (of the full-unit anchor 10 described above) for installation at the ends/edges of the surface area of the vessel shell that is to be protected (as described below) so that areas too small for a full-unit anchor 10 can still be protected without cutting and trimming an anchor down to size.
  • the anchor 110 includes a main body 112 and a mounting feature 114 for mounting to the thermal vessel to be protected.
  • the mounting feature 114 can be of the same design as that of the first embodiment, and the main body 112 can be of the same design as the first embodiment except as detailed below.
  • the main body 112 includes a central segment 116, two branch segments 118 extending from the central segment 116 (e.g., at spaced apart locations), two oppositely arranged extension segments 124 extending from the respective branch segments 118, and two reinforcement segments 128 (e.g., formed from adjacent branch and extension segments 118 and 124).
  • the central segment 116, branch segments 118, extension segments 124, and reinforcement segments 128 can be of the same design as those of the first embodiment, except that each end of the main body 112 has only one (instead of two) of the branch, extension, and reinforcement segments 118, 124, and 128.
  • the ramped transition 134 and other common features are typically also embodied in the anchor 110.
  • the invention relates to systems of plural thin- layer abrasion-resistant refractory anchoring devices.
  • the systems include a number of refractory anchors having unenclosed semi-polygonal cell openings, for example the full-unit anchors 10, the half-unit anchors 110, and/or any of the other anchors 10a-f disclosed herein, and in some embodiments can additionally or alternatively include other refractory anchors having unenclosed cell openings in semi-hexagonal or other semi-polygonal shapes.
  • the refractory anchoring devices are arranged in the refractory anchoring systems so that the unenclosed semi- hexagonal cell openings of adjacent ones of the anchoring devices cooperate to form substantially hexagonal cells (including regular hexagonal shapes and oblong ones) for retaining the refractory.
  • such refractory anchors can be arranged into systems to form cells having other polygonal shapes for retaining the refractory. Examples of such anchoring systems are shown in the figures described below, which are representative for explanatory purposes only and really only show portions of such anchoring systems and vessels, which are typically much larger and form an enclosure defining the thermal-process environment to be protected.
  • FIGS 13 and 13A show a first system 210 of the full-unit anchors 10 mounted to a vessel shell 2 in a first arrangement and ready for application of the refractory 4.
  • the anchors 10 are arranged in an ordered array of rows and columns to cooperatively define an ordered array of generally hexagonal cells 250 in a tessellated pattern.
  • Each of the generally hexagonal cells 250 is formed by two adjacent ones of the semi-hexagonal openings 22 of adjacent anchors 10, with each of the cells 250 having all six hexagonal sides formed at least in part by a segment (central 16, branch 18, or extension 24) of one of the anchors 10.
  • the adjacent anchors 10 there are spaces between the adjacent anchors 10 (so the cells 250 are not completely bounded or “closed,” and are thus at least partially open), however, at least four of the six hexagonal cell sides are formed in their entirely by one of the anchor segments, and no more than two are not, with those two hexagonal cell non-contiguous (i.e., open) sides having the majority of their lengths formed by two adjacent anchor extension segments and the anchor spacings providing flow passageways between adjacent cells 250 for the refractory 4 to flow (during installation) and interlink the adjacent cells (after curing, for use).
  • the central segments 16 of each of the anchors 10 in each column are in substantial alignment, with the free ends/edges 25 of the extension segments 24 of adjacent anchors 10 in substantial alignment but spaced apart, so that the end openings 22 of adjacent anchors 10 in the same column together define one of the cells 250.
  • the spacing between the adjacent extension-segment free ends/edges 25 in each column is far/large enough to ensure no physical contact during thermal expansion and contraction during high-temperature use and further to provide a passageway for refractory to flow during installation to interlink the refractory in adjacent end-formed cells, but typically close/small enough to maintain good surface contact between the anchors and the refractory by minimizing spaces in the cells free of any part of the anchors and further to keep the end-formed cells generally hexagonal.
  • the spacing between the extension segment ends/edges 25 is typically less than (or about the same as) the length of each of the extension segments 24 (e.g., about 5 mm to about 10 mm) but long enough that the end-formed cells 250 are slightly oblong in their generally hexagonal shape, as depicted.
  • the spacing is usually about 2 mm to about 20 mm, typically about 10 mm to about 15 mm, and most typically about 15 mm.
  • central segments 16 of each of the anchors 10 in each row are in a side-by-side parallel alignment, with the extension segments 24 of adjacent anchors 10 in a side-by-side parallel alignment but spaced apart, so that the central/side openings 22 of adjacent anchors 10 in the same row together define one of the central- formed cells 250.
  • the spacing between the adjacent parallel extension segments 24 in each row is far/large enough to ensure no physical contact during thermal expansion and contraction during high-temperature use and further to provide a passageway for refractory to flow during installation to interlink the refractory in adjacent central-formed cells, but typically close/small enough to maintain good surface contact between the anchors and the refractory by minimizing spaces in the cells free of any part of the anchors and further to keep the central-formed cells generally hexagonal.
  • the spacing between the adjacent parallel extension segments 24 in each row is typically about the same as the spacing between the adjacent extension-segment ends/edges 25 in each column such that the central-formed cells 250 are slightly oblong in their generally hexagonal shape, as depicted.
  • substantially hexagonal-shaped cells 250 Without regard to forming substantially hexagonal-shaped cells 250, and based simply on industry standards, the spacing is usually about 2 mm to about 20 mm, typically about 10 mm to about 15 mm, and most typically about 15 mm. [0069]
  • the result is an array of generally hexagonal refractory-holding cells that is installed without any time-consuming and/or difficult rolling or fitting steps required. Also, the risk of biscuiting is reduced because the individual anchors 10 are each individually mounted to the vessel shell 2 and spaced apart sufficiently that the thermal-stress effects of vessel expansion and contraction are minimized.
  • anchors 10 are spaced apart in each column and in each row, and also by including optional features such as the body voids (e.g., flow-through passageways) and/or the underbody gaps (e.g., flow-under passageways).
  • body voids e.g., flow-through passageways
  • underbody gaps e.g., flow-under passageways.
  • a more robust anchor-and-refractory protective barrier system is achieved, for example because of the resulting six-sided hex cells, and also by including optional features such as the reinforcements (e.g., two in each resulting hex cell), the body voids (e.g., where the reinforcements vacated), and/or the underbody gaps (e.g., under the central segments).
  • the refractory protects the metal anchors from chemical attack, so less metal material means less opportunities/locations for potential failures.
  • the flow passageways between adjacent semi-hex cells of adjacent anchors including the body voids, the underbody gaps, and the adjacent-anchor spacings, provide the benefits of interlinked refractory for better holding/retention and of less metal used for less coking/failure.
  • the resulting generally hexagonal cells 250 are not perfectly hexagonal but instead are slightly oblong (e.g., irregular or non-equilateral).
  • the cells 250 of this embodiment are generally hexagonal for familiarity to customers, but it is not necessary for the cells to be perfectly or even generally (including oblong) hexagonal in shape.)
  • the generally hexagonal cells 250 formed by adjacent central openings are oblong/elongate and oriented at 90 degrees from the generally hexagonal oblong/elongate cells 250 formed by adjacent end openings (i.e., each oblong/elongate central-formed cell 250 is rotated by 90 degrees relative to the four adjacent oblong/elongate end-formed cells).
  • Figure 14 shows a second system 310 of the full-unit anchors 10 and the half-unit anchors 110 mounted to a vessel shell 2 in a second arrangement and ready for application of the refractory.
  • This second system 310 is similar to the first system 210, with the anchors 10 arranged in an ordered array to cooperatively define at least some substantially hexagonal cells 350 in a tessellated pattern, except as noted herein.
  • alternating columns of the anchors 10 are shifted or offset so that the central segments 16 of adjacent anchors 10 in adjacent columns do not align (in embodiments with a 90-degree-rotated anchor orientation, the rows are shifted/offset).
  • the free/outer ends 25 of two extension segments 18 of adjacent anchors 10 in the same column are received in (or at the edge of) the end opening 22 of an adjacent anchor 10 in an adjacent column.
  • the free/outer edges 25 of the extension segments 18 of the anchors 10 in two adjacent columns can all be in an offset alignment with each other, as indicated by the vertical broken line in Figure 14.
  • the shift or offset can be less than one-half of an anchor, so that the central segment 16 of one anchor 10 is aligned with an extension segment 18 of an anchor in the adjacent column (instead of being centered between extension segments 18 of adjacent anchors 10 in the adjacent column), as indicated by the horizontal broken lines in Figure 14.
  • the system 310 additionally includes a number of the halfunit anchors 110 positioned at edges of the vessel surface 2 to be protected.
  • These anchors 100 are well-suited for use to fill a margin that is too small for the full-size anchors 10, for example the half-unit anchors 110 can be oriented at 90 degrees relative to the full-size anchors 10 and arranged in a column, for example as shown in the right margin of Figure 14.
  • the half-unit anchors 110 can be positioned at the ends of the columns of full-size anchors 10 that are offset or shifted, for example as shown at the top and bottom of the center column of full-unit anchors 10 of Figure 14.
  • FIG. 15 shows a third system 410 of the anchors 10 and modified anchors 10a of a third example embodiment mounted to a vessel shell in a third arrangement and ready for application of the refractory.
  • This third system 410 is substantially similar to the first system 210, with the anchors 10 and 10a arranged in an ordered array to cooperatively define some or all substantially hexagonal cells 450 in a tessellated pattern, except as noted herein.
  • the modified anchors 10a do not include the extension segments (which are included in the full units 10) extending from their branch segments 18a, and the anchors 10 and 10a are arrayed in an alternating fashion with a column of modified anchors 10a between columns of anchors 10.
  • This system 410 provides substantially the same arrangement as the first system 210, except with fewer extension segments, though at the expense of having two different anchors designs/parts to complete the anchoring system 410.
  • Figure 16 shows a fourth system 510 of modified/alternative anchors 10b of a fourth example embodiment mounted to a vessel shell in a fourth arrangement and ready for application of the refractory.
  • This fourth system 510 is substantially similar to the third system 410, with the anchors 10b arranged in an ordered array to cooperatively define some or all substantially hexagonal cells 550 in a tessellated pattern, except as noted herein.
  • the modified anchors 10b include the extension segments 24b on two diagonally opposite (cater-corner) branch segments 18b and do not include the extension segments on the other two diagonally opposite branch segments 18b.
  • This system 510 provides substantially the same arrangement as the third system 410, except with only one anchor design/part needed to complete the anchoring system 510.
  • FIG. 17 shows a fifth system 610 of modified/alternative anchors 10c of a fifth example embodiment mounted to a vessel shell in a fifth arrangement and ready for application of the refractory.
  • This fifth system 610 is substantially similar to the fourth system 510, with the anchors 10c arranged in an ordered array to cooperatively define some or all substantially hexagonal cells 650 in a tessellated pattern, except as noted herein.
  • the modified anchors 10c include the extension segments 24c on two diagonally opposite (cater-corner) branch segments 18c and do not include the extension segments on the other two diagonally opposite branch segments, as in the fourth system 510, and further the branch segments 18c without extension segments are shorter than those with them, so the extension segments of adjacent anchors 10c can be aligned in the manner depicted.
  • This system 610 provides substantially the same arrangement as the fourth system 510, except with the anchors 10c arranged to form a regular hexagonal shape.
  • FIGS 18-19 show a portion of a modified/alternative anchor 10d of a sixth example embodiment.
  • the anchor 10d is substantially similar to those of the previously described embodiments, except as noted herein.
  • the body includes voids 30d extending continuously through the central segment 16d and the branch segments 18d, in addition to the voids extending continuously through the branch segments 18d and the extension segments 24d, and the underbody gaps (at the bottom of the central and branch segments) are eliminated (as depicted) or reduced/minimized.
  • the anchor 10d has refractory flow passageways extending through and along the central, branch, and extension segments 16d, 18d, and 24d in a continuous manner except where the reinforcement segments 28d interrupt them (and adjoin two of the void ends).
  • Figure 20 shows a portion of a modified/alternative anchor 10e of a seventh example embodiment.
  • the anchor 10e is substantially similar to that of the sixth embodiment, except as noted herein.
  • the body includes voids 30e extending continuously through and along the central, branch, and extension segments 16e, 18e, and 24e, the reinforcement segments 28e have voids 29e that at least partially align and communicate with the body voids 30e (so there is not mechanical interference (obstruction or interruption) between them), and the underbody gaps (at the bottom of the central and branch segments) are eliminated (as depicted) or reduced/minimized.
  • the anchor 10e has a refractory flow passageway extending through and along the central, branch, and extension segments 16e, 18e, and 24e in a continuous manner, without interruption by the reinforcement segments 28e because of their voids 29e, which provide an additional flow passageway for additional refractory flow-through and retention.
  • FIG. 21-27 there is shown a modified refractory anchoring device 10f according to an eighth example embodiment.
  • the anchor 10f is substantially similar to the other embodiments disclosed herein, except as noted below.
  • the anchor 10f includes a main body 12f and a mounting feature 14f for mounting to the thermal vessel to be protected.
  • the main body 12f and the mounting feature 14f can be of the same basic design as the other embodiments disclosed herein, except they are provided as two parts connectable together instead of as a single integral part.
  • the main body 12f includes the central and branch extension segments 16f and 18f, and at least one of the extension segments 24f, and can also include the voids, reinforcement segments, and/or underbody gaps described herein.
  • the mounting feature 14f can include a mounting stud 38f for stud-welding.
  • the main body 12f and the mounting feature 14f are two separate parts that can be connectable together. In this way, the main body 12f and the mounting feature 14f can be made of two different materials.
  • This multipiece design of the anchor 10f is particularly desirable in applications in which the thermal vessel being protected is pressurized and/or must meet a related weld code (e.g., ASTM, ANSI, and California Weld Code for pressure vessels), for example in petrochemical processes (reactor side).
  • a related weld code e.g., ASTM, ANSI, and California Weld Code for pressure vessels
  • This multi-piece design enables the stud 38f to be made of the same material (or the same base/primary material) as the thermal vessel wall/shell to provide for longer-lasting weld/attachment, and the main body 12f to be made of a different material selected for chemical resistance and reaction (relative to the refractory material), thermal cycling, etc., to provide for longer-lasting refractory retention.
  • the bi-metallic anchors 10f have a longer life/time before they need to be replaced.
  • the main body 14f is made from one of carbon steel or stainless steel 304, 308, 309, 310, 316, 321 , 330, 410, 41 OS, and 601 , and the stud 38f is made from another one of those grades of steel.
  • the stud 38f can be made of a metal alloy of carbon steel and stainless steel 308 and the main body 12f of a different metal alloy of carbon steel and stainless steel (such as stainless steel 304 or another grade and/or series of steel).
  • the main body 12f and the stud 38f are made from different ones of any 3xx, 4xx, or 6xx series steel.
  • the main body 12f and mounting stud 38f can be made using conventional manufacturing equipment and techniques.
  • the main body 12f and the welding stud 38f are made of the same material, such as a single metal alloy (e.g., carbon steel and stainless steel such a 300 or 600 series). And in still other embodiments, the main body and the welding stud are made of a single component piece of a material, such as a single metal alloy that is sand-cast (or otherwise fabricated by single-use molds) into a one-piece part.
  • a single metal alloy e.g., carbon steel and stainless steel such a 300 or 600 series.
  • the main body and the welding stud are made of a single component piece of a material, such as a single metal alloy that is sand-cast (or otherwise fabricated by single-use molds) into a one-piece part.
  • the main body 12f and the mounting feature 14f are modified to include a coupling so they can be provided as two separate parts that can be connected together.
  • the main body 12f includes a collar 44f with a bore and internal helical threads 46f
  • the mounting feature 14f includes the mounting stud 38f with external helical threads 48f that screwmate with the collar threads 46f.
  • the collar 44f is typically centrally positioned on and integrally formed with the central segment 16f, with an open bottom to receive the stud 38f, and with a closed top to limit the depth of insertion of the stud 38f into the collar 44f.
  • the stud 38f includes an upper portion, opposite the lower portion where an studwelding interface/pilot element is located, with the external threads 48f formed on the stud upper portion.
  • the anchor 10f is typically provided in an assembled state, with the main body 12f and mounting stud 38f assembled together, ready for installation, though the two parts can be provided separately for assembly on site.
  • the invention in another aspect, relates to a method of protecting thermal vessels with refractory linings by installing systems of refractory anchoring devices having unenclosed semi-polygonal openings to form anchor systems having polygonal cells for retaining the refractory.
  • the method can include installing a number of the fullunit anchors 10, the half-unit anchors 110, and/or any of the other anchors 10a-f disclosed herein having unenclosed semi-hexagonal openings, and in some embodiments can additionally include installing other refractory anchors having unenclosed openings with other semi-polygonal shapes.
  • the method when using the anchors 10, includes individually positioning each of the anchors 10 relative to the vessel shell and individually mounting them in place so that the semi-hexagonal openings 22 of adjacent anchoring devices 10 cooperate to form an ordered array/system 210 of generally hexagonal-shaped cells 250.
  • the refractory anchoring devices 10 include a single studwelding stud 38 and the mounting process includes stud-welding the anchor devices 10 in place. The method contributes to providing the advantages of the anchors and anchor systems as described herein. The refractory can then be installed into the generally hexagonal cells 250 to complete the refractory lining process for the thermal vessel.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Furnace Housings, Linings, Walls, And Ceilings (AREA)

Abstract

La présente invention concerne des dispositifs d'ancrage réfractaires comprenant un corps principal et un élément de montage destiné à être monté sur un récipient thermique. Le corps principal a la forme de deux Y mis bout à bout formant un segment central, des segments de ramification s'étendant à partir des extrémités du segment central, et des segments d'extension s'étendant à partir des segments de ramification, pour former collectivement quatre ouvertures de cellule non fermées qui sont de forme semi-hexagonale. Certains modes de réalisation comprennent des segments de renforcement s'étendant dans des ouvertures de cellule respectives, des vides s'étendant à travers des segments de ramification et d'extension adjacents respectifs, un espace de sous-corps sous le segment central, un goujon de soudage de goujon unique pour l'élément de montage, et/ou un raccordement de collier et de goujon entre le corps principal d'ancrage et un goujon de soudage de goujon de l'élément de montage. Des systèmes et des procédés d'ancrage réfractaires comprennent un réseau des dispositifs d'ancrage réfractaires agencés et montés de telle sorte que les ouvertures de cellules semi-hexagonales non fermées de dispositifs d'ancrage adjacents forment de manière coopérative des cellules sensiblement hexagonales.
PCT/US2023/077324 2022-10-19 2023-10-19 Dispositif et système d'ancrage réfractaire WO2024086732A1 (fr)

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US17/968,934 US20230041165A1 (en) 2018-08-08 2022-10-19 Refractory anchor device and system

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6393789B1 (en) * 2000-07-12 2002-05-28 Christopher P. Lanclos Refractory anchor
US20180320973A1 (en) * 2017-05-05 2018-11-08 Exxonmobil Research And Engineering Company Refractory anchor assembly and method for installing the same
US20200078762A1 (en) * 2017-03-24 2020-03-12 Total Raffinage Chimie Anchoring Structure for an Anti-Erosion Coating, in Particular for Protecting a Wall of an FCC Unit
US10907899B1 (en) * 2019-02-26 2021-02-02 Christopher P. Lanclos Refractory anchor
US20220205720A1 (en) * 2019-04-26 2022-06-30 Silicon Refractory Anchoring Systems B.V. A refractory anchor
US20230041165A1 (en) * 2018-08-08 2023-02-09 Brand Shared Services, Llc Refractory anchor device and system

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6393789B1 (en) * 2000-07-12 2002-05-28 Christopher P. Lanclos Refractory anchor
US20200078762A1 (en) * 2017-03-24 2020-03-12 Total Raffinage Chimie Anchoring Structure for an Anti-Erosion Coating, in Particular for Protecting a Wall of an FCC Unit
US20180320973A1 (en) * 2017-05-05 2018-11-08 Exxonmobil Research And Engineering Company Refractory anchor assembly and method for installing the same
US20230041165A1 (en) * 2018-08-08 2023-02-09 Brand Shared Services, Llc Refractory anchor device and system
US10907899B1 (en) * 2019-02-26 2021-02-02 Christopher P. Lanclos Refractory anchor
US20220205720A1 (en) * 2019-04-26 2022-06-30 Silicon Refractory Anchoring Systems B.V. A refractory anchor

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