Refractory anchor device and system

Abstract

An anchoring device includes a main body configured to extend around an edge of a thermal vessel. The main body includes a mounting element comprising an outer surface and a mounting surface. The main body includes a first segment extending in a first direction. The first segment includes a first segment outer surface and a first segment inner surface. The main body includes a second segment. The second segment includes a mounting portion extending in a second direction from the mounting element. The second segment includes an extension portion extending from the mounting portion. The second segment includes a second segment outer surface and a second segment inner surface. The outer surface, the first segment outer surface, and a section of the second segment outer surface form a planar outer surface. The mounting element, the first segment, and the second segment are disposed in a plane.

Description

REFRACTORY ANCHOR DEVICE AND SYSTEMCROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] The present application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 578,907, filed August 25, 2023, which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure 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.BACKGROUND

[0003] Thermal-process vessels used in oil refineries and other petrochemical and chemical process facilities have highly abrasive and high-temperature environments. To protect the vessel shells (e.g., sidewalls), their internal surface is typically lined with a refractory material such as a thin layer of concrete.SUMMARY

[0004] One embodiment is directed to an anchoring device for a refractory material for lining a thermal vessel. The anchoring device includes a main body having an L-shape configured to extend at least partially around an edge of the thermal vessel. The main body includes a mounting element comprising an outer surface and a mounting surface. The main body includes a first segment extending from the mounting element in a first direction. The first segment includes a first segment outer surface and a first segment inner surface. The main body includes a second segment extending from the mounting element. The second segment includes a mounting portion extending in a second direction from the mounting element. The second direction is opposite the first direction. The second segment includes an extension portion extending from the mounting portion in a third direction. The third direction is different from the second direction. The second segment includes a second segment outer surface extending along the mounting portion and the extension portion. The second segment includes a second segment inner surface extending along the mounting portion and the extension portion. The outer surface, the first segment outersurface, and a section of the second segment outer surface form a planar outer surface. The mounting element, the first segment, and the second segment are disposed in a plane.

[0005] Another embodiment is directed to an anchoring device for a refractory material for lining a thermal vessel. The anchoring device includes a main body configured to extend at least partially around an edge of the thermal vessel. The main body includes a mounting element comprising an outer surface and a mounting surface. The main body includes a first segment extending from the mounting element. The first segment includes a first mounting portion extending in a first direction from the mounting element. The first segment includes a first branch portion extending from the first mounting portion at an obtuse angle relative to the first mounting portion. The first segment includes a first end portion extending from the first branch portion parallel with the first mounting portion. The main body includes a second segment extending from the mounting element. The second segment includes a second mounting portion extending in a second direction from the mounting element. The second direction is opposite the first direction. The second mounting portion includes a bend. The second segment includes an extension portion extending from the first mounting portion in a third direction. The second segment includes a second branch portion extending from the extension portion at an obtuse angle relative to the extension portion. The second segment includes a second end portion extending from the second branch portion parallel with the extension portion. The mounting element, the first mounting portion, the second mounting portion, and the extension portion are disposed in a plane.

[0006] Another embodiment is directed to an anchoring device for a refractory material for lining a thermal vessel. The anchoring device incudes a main body configured to extend at least partially around an edge of the thermal vessel. The main body include a mounting element comprising an outer surface and a mounting surface. The main body includes a first segment extending from the mounting element. The first segment includes a first mounting portion extending in a first direction from the mounting element. The first segment includes a plurality of first branch portions extending from the first mounting portion at an obtuse angle relative to the first mounting portion. The first segment includes a plurality of first end portions. Each of the plurality of first end portions extends from a corresponding first branch portion of the plurality of branch portions. The plurality of first end portions extend parallel with the first mounting portion. The main body includes a second segment extending from the mounting element. The secondsegment includes a second mounting portion extending in a second direction from the mounting element. The second direction is opposite the first direction. The second mounting portion includes a bend. The second segment includes an extension portion extending from the first mounting portion in a third direction. The second segment includes a plurality of second branch portions extending from the extension portion at an obtuse angle relative to the extension portion. The second segment includes a plurality of second end portions, each extending from a corresponding second branch portion of the plurality of second branch portions. The plurality of second end portions extend parallel with the extension portion. The mounting element, the first mounting portion, the second mounting portion, and the extension portion are disposed in a plane.[0007| These and other aspects and implementations are discussed in detail below. The foregoing information and the following detailed description include illustrative examples of various aspects and implementations, and provide an overview or framework for understanding the nature and character of the claimed aspects and implementations. The drawings provide illustration and a further understanding of the various aspects and implementations, and are incorporated in and constitute a part of this specification. The foregoing information and the following detailed description and drawings include illustrative examples and should not be considered as limiting.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The accompanying drawings are not intended to be drawn to scale. Like reference numbers and designations in the various drawings indicate like elements. For purposes of clarity, not every component may be labeled in every drawing.

[0009] FIG. l is a perspective view of an example refractory anchor, according to an example embodiment.

[0010] FIG. 2 is a bottom perspective view of the refractory anchor of FIG. 1.

[0011] FIG. 3 is a side view of the refractory anchor of FIG. 1.

[0012] FIG. 4 is a rear view of the refractory anchor of FIG. 1.

[0013] FIG. 5 is a bottom view of the refractory anchor of FIG. 1.

[0014] FIG. 6 is a perspective view of another example refractory anchor, according to an example embodiment.

[0015] FIG. 7 is a bottom perspective view of the refractory anchor of FIG. 6.

[0016] FIG. 8 is a side view of the refractory anchor of FIG. 6.

[0017] FIG. 9 is a rear view of the refractory anchor of FIG. 6.

[0018] FIG. 10 is a bottom view of the refractory anchor of FIG. 6.

[0019] FIG. 11 is a perspective view of another example refractory anchor, according to an example embodiment.

[0020] FIG. 12 is a bottom perspective view of the refractory anchor of FIG. 11.

[0021] FIG. 13 is a side view of the refractory anchor of FIG. 11.

[0022] FIG. 14 is a rear view of the refractory anchor of FIG. 11.

[0023] FIG. 15 is a bottom view of the refractory anchor of FIG. 11.

[0024] FIG. 16 is a perspective view of another example refractory anchor, according to an example embodiment.

[0025] FIG. 17 is a side view of the refractory anchor of FIG. 16.

[0026] FIG. 18 is a bottom view of the refractory anchor of FIG. 16.

[0027] FIG. 19 is a perspective view of another example refractory anchor, according to an example embodiment.

[0028] FIG. 20 is a side view of the refractory anchor of FIG. 19.

[0029] FIG. 21 is a bottom view of the refractory anchor of FIG. 19.

[0030] FIG. 22 is a perspective view of another example refractory anchor, according to an example embodiment.

[0031] FIG. 23 is a side view of the refractory anchor of FIG. 22.

[0032] FIG. 24 is a bottom view of the refractory anchor of FIG. 22.

[0033] FIG. 25 is a cross-sectional view of an example mounting element, according to an example embodiment.

[0034] FIG. 26 is a bottom perspective view of an example mounting element, according to an example embodiment.

[0035] FIG. 27 is a perspective view of an example array of refractory anchors of FIG. 6, according to an example embodiment.

[0036] FIG. 28 is a perspective view of an example array of refractory anchors of FIG. 11, according to an example embodiment.

[0037] FIG. 29 is a perspective view of an example array of refractory anchors of FIG. 16, according to an example embodiment.

[0038] FIG. 30 is a perspective view of an example array of refractory anchors of FIG. 19, according to an example embodiment.

[0039] FIG. 31 is a perspective view of an example array of refractory anchors of FIG. 22, according to an example embodiment.DETAILED DESCRIPTION

[0040] Following below are more detailed descriptions of various concepts related to, and implementations of, methods, apparatuses, and systems of anchoring devices for a refractory material for together forming a protective barrier system for a thermal vessel. The various concepts introduced above and discussed in greater detail below may be implemented in any of numerous ways.

[0041] The most common form of thin-layer abrasion-resistant refractory concrete anchoring system is called HEXMESH (aka “hexmetal” or just “hex”) anchor sheets. 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 strongattachment to the underlying vessel shell. Once welded, 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.

[0042] Over the decades that hex has been in use, several weaknesses in this system have been exposed. The hex and refractory system must move in concert with any flex that occurs in the vessel shell because the hex sheet is fitted and welded flush with and rigidly to the vessel shell. This makes the hex and refractory system prone to “biscuiting,” which means individual hex cells will tend to “pop” the refractory concrete out in a hexagonal biscuit shape when the vessel shell experiences thermal expansion or contraction. In addition, this can compromise the protective capabilities of the refractory concrete liner by opening gaps that allow catalysts, gases, carbon, and other process-related materials to contact the exposed portion of the vessel shell. This in turn can lead to further failure of the refractory concrete liner system and the need for premature replacement of extremely expensive process vessels and components. Furthermore, installing hex is very time-consuming, tedious, and cumbersome because of the large number of welds required and because the sheets must be cut on-site to custom-fit each vessel, beat into shape and place with a hammer, and sometimes cut into small pieces to fit through access openings to the work areas, with this being particularly an issue for irregularly shaped vessels.

[0043] Other refractory anchoring devices and systems include D-BAR anchors (e.g., U.S. Pat. No. 6,393,789), C-BAR anchors, and 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.

[0044] Accordingly, it can be seen that needs exist for improvements in anchoring devices, systems, and methods for refractory liners for thermal vessels. It is to the provision of solutions to these and other problems that the present disclosure is primarily directed.

[0045] Generally described, the present invention relates to anchoring devices, systems, and methods for a refractory material for together forming a protective barrier system for a thermal vessel. The anchoring devices, systems, and methods can be used for protecting thermal vesselssuch 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 devices, systems, and methods 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. And the anchoring devices, systems, and methods 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 preformed.

[0046] Referring to FIGS. 1-5, an example refractory anchor 100 is shown, according to an example embodiment. The refractory anchor 100 includes a main body 102. The main body 102 is configured to extend at least partially around an edge of a thermal vessel. The main body 102 may include an L-shape arrangement end-to-end. For example, the main body 102 may have a first portion extending in a first direction and a second portion extending from an end of the first portion at approximately a right angle to create an L-shape. The main body 102 includes a mounting element 104. The mounting element 104 may be configured to couple the refractory anchor 100 with a thermal vessel. The mounting element 104 may include a first surface, shown as outer mounting surface 106, and a second surface, shown as inner mounting surface 108. The outer mounting surface 106 is opposite the inner mounting surface 108. The inner mounting surface 108 is configured to confront or engage a mounting surface of the thermal vessel.

[0047] The main body 102 includes a first segment 110. The first segment 110 may extend from the mounting element 104 in a first direction. The first segment 110 is a straight (e.g., linear) segment extending away from the mounting element 104. The first segment 110 may be coupled with or integrally formed with the mounting element 104. The first segment 110 may be the same material as or a different material than the mounting element. The first segment 110 includes a first segment outer surface 112 and a first segment inner surface 114. The first segment outer surface 112 is opposite the first segment inner surface 114. The first segment inner surface 114 is configured to confront the mounting surface of the thermal vessel.

[0048] The main body 102 includes a second segment 116. The second segment 116 extends from the mounting element 104. The second segment 116 may be coupled with or integrally formed with the mounting element 104. The second segment 116 may be the same material as or a different material than the mounting element. The second segment 116 may include a mounting portion 118. The mounting portion 118 may extend from the mounting element 104 in a second direction. The second direction may be opposite the first direction of the first segment 110. The mounting portion 118 may include a bend 120.

[0049] The second segment 116 may include an extension portion 122. The extension portion 122 may extend from the mounting portion 118 in a third direction. The third direction may be different than the second direction. For example, the third direction may be perpendicular to the second direction.

[0050] The various portions of the second segment 116 may be coupled together or formed from a single component, or a combination thereof. For example, the second segment 116 may be a single piece of material with a plurality of bends to orient the portions in a desired orientation. As shown in FIG. 5, among others, the first segment 110 and the second segment 116 may comprise a thin profile. For example, the first segment 110 and the second segment 116 may comprise a single sheet or layer of material. The first segment 110 may have a first segment width 124. The second segment 116 may have a second segment width 126. The first segment width 124 may be the same as or different than the second segment width 126. The mounting element 104 may have a mounting element width 128. The mounting element width 128 may be greater than both the first segment width 124 and the second segment width 126.

[0051] The second segment 116 may include a second segment outer surface 130 and a second segment inner surface 132. The second segment outer surface 130 may extend along the mounting portion 118 and the extension portion 122. The second segment inner surface 132 may extend along the mounting portion 118 and the extension portion 122. The first segment outer surface 112, the outer mounting surface 106, and a section of the second segment outer surface 130 may form a planar outer surface. As shown in FIG. 4, among others, the first segment 110, the mounting element 104, and the second segment 116 may be disposed in a plane 134.

[0052] In some embodiments, the first segment inner surface 114, the inner mounting surface108, and the second segment inner surface 132 may define a pocket 136. The pocket 136 may beconfigured to receive at least a portion of a stud. The pocket 136 may allow for a larger stud to be used, which may improve the connection between the refractory anchor 100 and the thermal vessel. With the pocket 136, a mounting element depth 138 may be less than a first segment depth 140 (e.g., a maximum first segment depth 140) and less than a second segment depth 142 (e.g., a maximum second segment depth 142). The first segment depth 140 may be the same as or different than the second segment depth 142.

[0053] The mounting element 104 includes a recess 144. The recess 144 is configured to receive a first portion of a stud. The stud is configured to couple the refractory anchor 100 with the thermal vessel. The inner mounting surface 108 may be configured to interface with a second portion of the stud (e.g., a shoulder of the stud). At least a portion of the stud is disposed in the pocket 136. In some embodiments, the mounting element 104 may be integrally formed with the stud.

[0054] The refractory anchor 100 may include at least one opening or aperture, shown as void 146. The void 146 may extend through a portion of the main body 102. The void 146 may be configured to allow refractory to flow through the main body 102 when the refractory anchor 100 is mounted to the thermal vessel and the refractory is being installed. The main body 102 may include a plurality of voids 146. For example, the first segment 110 may include a first void 146. The second segment 116 may include a second void 146 and a third void 146. The second void 146 may be disposed on the mounting portion 118. The third void 146 may be disposed on the extension portion 122.

[0055] The main body 102 may include at least one reinforcement segment, shown as tab 148. The tab 148 may correspond with a void 146. In some embodiments, the tabs 148 may be linear and extend away from the main body 102. The tabs 148 may provide additional contact surface area for engaging and securing the refractory in place. The tabs 148 may protrude from the main body 102 to reduce unobstructed distances within the refractory, thereby better securing the refractory in the cells and helping reduce the likely incidence of biscuiting of the refractory. In some embodiments, the tabs 148 extend at an acute angle, at an obtuse angle, or perpendicular to the corresponding segment. In some embodiments, the refractory anchor 100 has no tabs 148, or a subset of the voids 146 have tabs 148.

[0056] In some embodiments, the main body 102 may have at least one segment end 150. The segment end 150 may be disposed at an end of the first segment 110 or the second segment 116. The segment end 150 may include at least one indented region 152. The indented region 152 may have a curved surface.

[0057] Referring to FIGS. 16-18, in some embodiments the recess 144 and the pocket 136 are omitted, and the mounting element 104 may define a longer length or height (e.g., the mounting element depth 138 of FIGS. 16-18 is greater than the mounting element depth 138 of FIGS. 1-5). For example, the mounting element depth 138 may be greater than the first segment depth 140 and greater than the second segment depth 142. In this embodiment, the inner mounting surface 108 of the mounting element 104 is configured to couple to the mounting surface of the thermal vessel. That is, rather than using a separate stud that is coupled to the mounting element 104 and then welded to the thermal vessel, the mounting element 104 is welded directly to the thermal vessel.

[0058] Referring to FIGS. 6-10, an example refractory anchor 200 is shown, according to an example embodiment. The refractory anchor 200 includes a main body 202. The main body 202 is configured to extend at least partially around an edge of a thermal vessel. The main body 202 includes a mounting element 204. The mounting element 204 may be configured to couple the refractory anchor 200 with a thermal vessel. The mounting element 104 may include a first surface, shown as outer mounting surface 206, and a second surface, shown as inner mounting surface 208. The outer mounting surface 206 is opposite the inner mounting surface 208. The inner mounting surface 208 is configured to confront the mounting surface of the thermal vessel.

[0059] The main body 202 includes a first segment 210. The first segment 210 may extend from the mounting element 204. The first segment 210 is a non-linear (e.g., bent, curvy, etc.) segment extending away from the mounting element 204. The first segment 210 may be coupled with or integrally formed with the mounting element 204. The first segment 210 may be the same material as or a different material than the mounting element 204.

[0060] The first segment 210 may include a first mounting portion 212. The first mounting portion 212 may extend in a first direction from the mounting element 204. The first segment 210 may include a first branch portion 214. The first branch portion 214 may extend from the first mounting portion 212 at an obtuse angle relative to the first mounting portion 212. The firstsegment 210 may include a first end portion 216. The first end portion 216 may extend from the first branch portion 214 parallel with the first mounting portion 212. The first segment 210 may include a first segment outer surface 218 and a first segment inner surface 220. The first segment outer surface 218 is opposite the first segment inner surface 220. The first segment inner surface 218 is configured to confront the mounting surface of the thermal vessel. The first segment outer surface 218 may extend along the first mounting portion 212, the first branch portion 214, and the first end portion 216. The first segment inner surface 220 may extend along the first mounting portion 212, the first branch portion 214, and the first end portion 216.

[0061] The main body 202 includes a second segment 222. The second segment 222 extends from the mounting element 204. The second segment 222 may be coupled with or integrally formed with the mounting element 204. The second segment 222 may be the same material as or a different material than the mounting element 204. The second segment 222 may include a second mounting portion 224. The second mounting portion 224 may extend in a second direction from the mounting element 204. The second direction may be opposite the first direction of the first mounting portion 212. The second mounting portion 224 may include a bend 226. The second segment 222 may include an extension portion 228. The extension portion 228 may extend from the second mounting portion 224 in a third direction. The third direction may be different than the second direction. For example, the third direction may be perpendicular to the second direction. The second segment 222 may include a second branch portion 230. The second branch portion 230 may extend from the extension portion 228 at an obtuse angle relative to the extension portion 228. The second segment 222 may include a second end portion 232. The second end portion 232 may extend from the second branch portion 230 parallel with the extension portion 228.

[0062] The various portions of the first segment 210 and the second segment 222 may be coupled together or formed from a single component, or a combination thereof. For example, the first segment 210 or the second segment 222 may be a single piece of material with a plurality of bends to orient the portions in a desired orientation. As shown in FIG. 10, among others, the first segment 210 and the second segment 222 may comprise a thin profile. For example, the first segment 210 and the second segment 222 may comprise a single sheet or layer of material. The first segment 210 may have a first segment width 234. The second segment 222 may have a second segment width 236. The first segment width 234 may be the same as or different than thesecond segment width 236. The mounting element 204 may have a mounting element width 238. The mounting element width 238 may be greater than both the first segment width 234 and the second segment width 236.

[0063] The second segment 222 may include a second segment outer surface 240. The second segment outer surface 240 may extend along the second mounting portion 224, the extension portion 228, the second branch portion 230, and the second end portion 232. The second segment 222 may include a second segment inner surface 242. The second segment inner surface 242 may extend along the second mounting portion 224, the extension portion 228, the second branch portion 230, and the second end portion 232. The outer mounting surface 206, the first segment outer surface 218, and a portion of the second segment outer surface 240 may form a planar outer surface. As shown in FIG. 10, among others, the mounting element 204, the first mounting portion 212, the second mounting portion 224, and the extension portion 228 may be disposed in a first plane 244. As shown in FIG. 9, the first end portion 216 and the second end portion 232 may be disposed in a second plane 245. The second plane 245 may be offset from and parallel with the first plane 244.

[0064] In some embodiments, the first segment inner surface 220, the inner mounting surface 208, and the second segment inner surface 242 defines a pocket 246. The pocket 246 is configured to receive at least a portion of a stud. The pocket 246 may allow for a larger stud to be used, which may improve the connection between the refractory anchor 200 and the thermal vessel. With the pocket 246, a mounting element depth 248 may be less than a first segment depth 250 (e.g., a maximum first segment depth 250) and less than a second segment depth 252 (e.g., a maximum second segment depth 252). The first segment depth 250 may be the same as or different than the second segment depth 252.

[0065] The mounting element 204 may include a recess 254. The recess 254 may be configured to receive a first portion of a stud. The stud may be configured to couple the refractory anchor 200 with the thermal vessel. The inner mounting surface 208 may be configured to interface with a second portion of the stud (e.g., a shoulder of the stud). At least a portion of the stud may be disposed in the pocket 246. In some embodiments, the mounting element 204 may be integrally formed with the stud.

[0066] The refractory anchor 200 may include at least one opening or aperture, shown as void 256. The void 256 may extend through a portion of the main body 202. The void 256 may be configured to allow refractory to flow through the main body 202 when the refractory anchor 200 is mounted to the thermal vessel and the refractory is being installed. The main body 202 may include a plurality of voids 256. For example, the first segment 210 may include a first void 256. The second segment 222 may include a second void 256 and a third void 256. The second void 256 may be disposed on the second mounting portion 224. The third void 256 may be disposed on the second branch portion 230.

[0067] The main body 202 may include at least one reinforcement segment, shown as tab 258. The tab 258 may correspond with a void 256. In some embodiments, the tabs 258 may be linear and extend away from the main body 202. The tabs 258 may provide additional contact surface area for engaging and securing the refractory in place. The tabs 258 may protrude from the main body 202 to reduce unobstructed distances within the refractory, thereby better securing the refractory in the cells and helping reduce the likely incidence of biscuiting of the refractory. In some embodiments, the tabs 258 extend perpendicular to the corresponding segment. In some embodiments, the refractory anchor 200 has no tabs 258, or a subset of the voids 256 have tabs 258.

[0068] Referring now to FIGS. 19-21, in some embodiments the recess 254 and the pocket 246 are omitted, and the mounting element 204 may define a longer length or height (e.g., mounting element depth 248 of FIGS. 19-21 is greater than the mounting element depth 248 of FIGS. 6- 10). For example, the mounting element depth 248 may be greater than the first segment depth 250 and greater than the second segment depth 252. In this embodiment, the inner mounting surface 208 of the mounting element 204 is configured to couple to the mounting surface of the thermal vessel. That is, rather than using a separate stud that is coupled to the mounting element 204 and then welded to the thermal vessel, the mounting element 204 is welded directly to the thermal vessel.

[0069] Referring to FIGS. 11-15, an example refractory anchor 300 is shown, according to an example embodiment. The refractory anchor 300 includes a main body 302. The main body 302 is configured to extend at least partially around an edge of a thermal vessel. The main body 302 includes a mounting element 304. The mounting element 304 may be configured to couple the refractory anchor 300 with a thermal vessel. The mounting element 304 may include a firstsurface, shown as outer mounting surface 306, and a second surface, shown as inner mounting surface 308. The outer mounting surface 306 is opposite the inner mounting surface 308. The inner mounting surface 308 is configured to confront the mounting surface of the thermal vessel.

[0070] The main body 302 includes a first segment 310. The first segment 310 may extend from the mounting element 304. The first segment 310 is a non-linear (e.g., bent, curvy, etc.) segment extending away from the mounting element 304. The first segment 310 may be coupled with or integrally formed with the mounting element 304. The first segment 310 may be the same material as or a different material than the mounting element 304.

[0071] The first segment 310 may include a first mounting portion 312. The first mounting portion 312 may extend in a first direction from the mounting element 304. The first segment 310 may include a plurality of first branch portions 314. The first branch portions 314 may extend from the first mounting portion 312 at an obtuse angle relative to the first mounting portion 212. For example, one of the first branch portions 314 may extend from the first mounting portion 312 in a first direction at the obtuse angle and another of the first branch portions 314 may extend from the first mounting portion 312 in a second direction at the obtuse angle. The first segment 310 may include a plurality of first end portions 316. Each of the first end portions 316 may extend from a corresponding first branch portion 314. The first end portions 316 may extend parallel with the first mounting portion 312. The first segment 310 may include a first segment outer surface 318 and a first segment inner surface 320. The first segment outer surface 318 is opposite the first segment inner surface 320. The first segment inner surface 320 is configured to confront the mounting surface of the thermal vessel. The first segment outer surface 318 may extend along the first mounting portion 312, the first branch portions 314, and the first end portions 316. The first segment inner surface 320 may extend along the first mounting portions 212, the first branch portions 314, and the first end portions 316.

[0072] The main body 302 includes a second segment 322. The second segment 322 extends from the mounting element 304. The second segment 322 may be coupled with or integrally formed with the mounting element 304. The second segment 322 may be the same material as or a different material than the mounting element 304. The second segment 322 may include a second mounting portion 324. The second mounting portion 324 may extend in a second direction from the mounting element 304. The second direction may be opposite the first direction of the first mounting portion 312. The second mounting portion 324 may include a bend326. The second segment 322 may include an extension portion 328. The extension portion 328 may extend from the second mounting portion 324 in a third direction. The third direction may be different than the second direction. For example, the third direction may be perpendicular to the second direction.

[0073] The second segment 322 may include a plurality of second branch portions 330. The second branch portions 330 may extend from the extension portion 328 at an obtuse angle relative to the extension portion 328. For example, one of the second branch portions 330 may extend from the extension portion 328 in a first direction at the obtuse angle and another one of the second branch portions 330 may extend from the extension portion 328 in a second direction at the obtuse angle. The second segment 322 may include a plurality of second end portions 332. Each of the second end portions 332 may extend from a corresponding second branch portion 330. The second end portions 332 may extend parallel with the extension portion 328.

[0074] The various portions of the first segment 310 and the second segment 322 may be coupled together or formed from a single component, or a combination thereof. For example, the first segment 310 or the second segment 322 may be a single piece of material with a plurality of bends to orient the portions in a desired orientation. As shown in FIG. 15, among others, the first segment 310 and the second segment 322 may comprise a thin profile. For example, the first segment 310 and the second segment 322 may comprise a single sheet or layer of material. The first segment 310 may have a first segment width 334. The second segment 322 may have a second segment width 336. The first segment width 334 may be the same as or different than the second segment width 336. The mounting element 304 may have a mounting element width 338. The mounting element width 338 may be greater than both the first segment width 334 and the second segment width 336.

[0075] The second segment 322 may include a second segment outer surface 340. The second segment outer surface 340 may extend along the second mounting portion 324, the extension portion 328, the second branch portions 330, and the second end portions 332. The second segment 322 may include a second segment inner surface 342. The second segment inner surface 342 may extend along the second mounting portion 324, the extension portion 328, the second branch portions 330, and the second end portions 332. The outer mounting surface 306, the first segment outer surface 318, and a portion of the second segment outer surface 340 may form a planar outer surface. As shown in FIG. 15, among others the mounting element 304, the firstmounting portion 312, the second mounting portion 324, and the extension portion 328 may be disposed in a first plane 344. A first end portion 316 and a second end portion 332 may share a plane. For example, one of the first end portions 316 and one of the second end portions 332 may be disposed in a second plane 345. Another of the first end portions 316 and another of the second end portions 332 may be disposed in a third plane 346. The second plane 345 and the third plane 346 may be offset from and parallel with the first plane 344.

[0076] In some embodiments, the first segment inner surface 320, the inner mounting surface 308, and the second segment inner surface 342 define a pocket 347. The pocket 347 is configured to receive at least a portion of a stud. The pocket 347 may allow for a larger stud to be used, which may improve the connection between the refractory anchor 300 and the thermal vessel. With the pocket 347, a mounting element depth 348 may be less than a first segment depth 350 (e.g., a maximum first segment depth 350) and less than a second segment depth 352 (e.g., a maximum second segment depth 352). The first segment depth 350 may be the same as or different than the second segment depth 352.

[0077] The mounting element 204 includes a recess 354. The recess 354 is configured to receive a first portion of a stud. The stud is configured to couple the refractory anchor 300 with the thermal vessel. The inner mounting surface 308 may be configured to interface with a second portion of the stud (e.g., a shoulder of the stud). At least a portion of the stud may be disposed in the pocket 347. In some embodiments, the mounting element 304 may be integrally formed with the stud.

[0078] The refractory anchor 300 may include at least one opening or aperture, shown as void 356. The void 356 may extend through a portion of the main body 302. The void 356 may be configured to allow refractory to flow through the main body 302 when the refractory anchor 300 is mounted to the thermal vessel and the refractory is being installed. The main body 302 may include a plurality of voids 356. For example, the main body 302 may include a first void 356, a second void 356, and a third void 356. The first void 356 may extend between a first branch portion 314 and a first end portion 316. The second void 356 may be disposed on the second mounting portion 324. The third void 356 may extend between a second branch portion 330 and a second end portion 332.

[0079] The main body 302 may include at least one reinforcement segment, shown as tab 358. The tab 358 may correspond with a void 356. In some embodiments, the tabs 358 may be linear and extend away from the main body 302. The tabs 358 may provide additional contact surface area for engaging and securing the refractory in place. The tabs 358 may protrude from the main body 302 to reduce unobstructed distances within the refractory, thereby better securing the refractory in the cells and helping reduce the likely incidence of biscuiting of the refractory. In some embodiments, the tabs 358 extend perpendicular to the corresponding segment. In some embodiments, the refractory anchor 300 has no tabs 358, or a subset of the voids 356 have tabs 358.

[0080] Referring now to FIGS. 22-24, in some embodiments the recess 354 and the pocket 347 are omitted and the mounting element 304 may define a longer length or height (e.g., the mounting element depth 348 of FIGS. 22-24 is greater than the mounting element depth 348 of FIGS. 11-15). For example, the mounting element depth 348 may be greater than the first segment depth 350 and greater than the second segment depth 352. In this embodiment, the inner mounting surface 308 of the mounting element 304 is configured to couple to the mounting surface of the thermal vessel. That is, rather than using a separate stud that is coupled to the mounting element 304 and then welded to the thermal vessel, the mounting element 304 is welded directly to the thermal vessel.

[0081] Referring to FIG. 25, a mounting element 400 is shown, according to an example embodiment. Mounting elements 104, 204, 304 may be or include mounting element 400. In some embodiments, such as FIGS. 1-15, the mounting element 400 is the mounting element 104, the mounting element 204, or the mounting element 304, and the stud 402 is configured to be coupled within the mounting element 400. For example, the mounting element 400 may have an inner mounting surface 404 and include or define a recess 406. The stud 402 may have a first portion 408 and a second portion 410. The first portion 408 may be configured to be disposed in the recess 406. The second portion 410 may be configured to interface with the inner mounting surface 404. The stud 402 is configured to be coupled with the mounting surface of the thermal vessel, and the mounting element 400 is configured to couple with the stud 402. The stud 402 may be created from a different material than the main body 102, 202, 302 of the refractory anchor 100, 200, 300 (e.g., to avoid the formation of brittle chromium carbine, etc.).

[0082] Referring to FIG. 26, a mounting element 500 is shown, according to an example embodiment. Mounting elements 104, 204, 304 may be or include mounting element 500. In some embodiments, such as in FIGS. 16-26, the mounting element 500 is the mounting element 104, the mounting element 204, or the mounting element 304, and is integrally formed (e.g., monolithic, unitary, etc.) with the body 102, 202, 302, respectively (e.g., cast as a single body, etc.). For example, instead of comprising a recess 406 to couple with a stud 402, the mounting element 500 may comprise a single body 502 configured to couple a refractory anchor 100, 200, 300 with a thermal vessel.

[0083] Referring to FIGS. 27-31, a plurality of refractory anchor arrays are shown, according to example embodiments. A plurality of refractory anchors 100, 200, 300 can be applied or installed for a single thermal vessel to create a refractory anchor array. For example, as shown in FIG. 29, a refractory anchor array 2000 may include a plurality of refractory anchors 100 configured to couple with the thermal vessel 1802. The orientation of the components of the refractory anchor 100 allows the refractory anchor 100 to extend at least partially over an edge 1804 of the thermal vessel 1802. As such, other refractory anchors do not need to be specially made or cut or modified to accommodate an edge 1804 of a thermal vessel 1802. The refractory anchors 100 forms a gap between the thermal vessel 1802 and the main body 102. The gap is configured to allow refractory to flow between the main body 102 and the thermal vessel 1802. The mounting element 104, 500 is configured to couple to the thermal vessel 1802.

[0084] As shown in FIGS. 27 and 30, a refractory anchor array 1900 may include a plurality of refractory anchors 200 configured to couple with the thermal vessel 1802. The orientation of the components of the refractory anchor 200 allows the refractory anchor 200 to extend at least partially over an edge 1804 of the thermal vessel 1802. As such, other refractory anchors do not need to be specially made or cut or modified to accommodate an edge 1804 of a thermal vessel 1802. The second branch portion 230 and the first branch portion 214 may prevent the propagation of cracks in the refractory material (e.g., the crack would extend between the first branch portion 214 and the second branch portion 230 instead of extending to another refractory anchor). The refractory anchors 200 forms a gap between the thermal vessel 1802 and the main body 202. The gap is configured to allow refractory to flow between the main body 202 and the thermal vessel 1802. In FIG. 27, the stud 402 is configured to couple with the thermal vessel 1802, and the mounting element 400 is configured to couple the refractory anchor 200 with thestud 402. In FIG. 30, the mounting element 204, 500 is configured to couple the refractory anchor 200 to the thermal vessel 1802.

[0085] As shown in FIGS. 28 and 31, a refractory anchor array 1800 may include a plurality of refractory anchors 300 configured to couple with a thermal vessel 1802. The orientation of the components of the refractory anchor 300 allows the refractory anchor 300 to extend at least partially over an edge 1804 of the thermal vessel 1802. As such, other refractory anchors do not need to be specially made or cut or modified to accommodate an edge 1804 of a thermal vessel 1802. The first branch portion 314 and the second branch portion 330 may further prevent the propagation of cracks in the refractory material (e.g., the crack would extend between the first branch portion 314 and the second branch portion 330 instead of extending to another refractory anchor). The refractory anchors 300 forms a gap between the thermal vessel 1802 and the main body 302. The gap is configured to allow refractory to flow between the main body 302 and the thermal vessel 1802. In FIG. 28, the stud 402 is configured to couple with the thermal vessel 1802, and the mounting element 400 is configured to couple the refractory anchor 300 with the stud 402. In FIG. 31, the mounting element 304, 500 is configured to couple the refractory anchor 300 with the thermal vessel 1802.

[0086] Having now described some illustrative implementations, it is apparent that the foregoing is illustrative and not limiting, having been presented by way of example. In particular, although many of the examples presented herein involve specific combinations of method acts or system elements, those acts and those elements may be combined in other ways to accomplish the same objectives. Acts, elements and features discussed in connection with one implementation are not intended to be excluded from a similar role in other implementations or implementations.

[0087] The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including” “comprising” “having” “containing” “involving” “characterized by” “characterized in that” and variations thereof herein, is meant to encompass the items listed thereafter, equivalents thereof, and additional items, as well as alternate implementations consisting of the items listed thereafter exclusively. In one implementation, the systems and methods described herein consist of one, each combination of more than one, or all of the described elements, acts, or components.

[0088] Any references to implementations or elements or acts of the systems and methods herein referred to in the singular may also embrace implementations including a plurality of these elements, and any references in plural to any implementation or element or act herein may also embrace implementations including only a single element. References in the singular or plural form are not intended to limit the presently disclosed systems or methods, their components, acts, or elements to single or plural configurations. References to any act or element being based on any information, act or element may include implementations where the act or element is based at least in part on any information, act, or element.

[0089] Any implementation disclosed herein may be combined with any other implementation or embodiment, and references to “an implementation,” “some implementations,” “one implementation” or the like are not necessarily mutually exclusive and are intended to indicate that a particular feature, structure, or characteristic described in connection with the implementation may be included in at least one implementation or embodiment. Such terms as used herein are not necessarily all referring to the same implementation. Any implementation may be combined with any other implementation, inclusively or exclusively, in any manner consistent with the aspects and implementations disclosed herein.

[0090] References to “or” may be construed as inclusive so that any terms described using “or” may indicate any of a single, more than one, and all of the described terms. References to at least one of a conjunctive list of terms may be construed as an inclusive “or” to indicate any of a single, more than one, and all of the described terms. For example, a reference to “at least one of ‘A’ and ‘B’” can include only ‘A’, only ‘B’, as well as both ‘A’ and ‘B’. Such references used in conjunction with “comprising” or other open terminology can include additional items.

[0091] Where technical features in the drawings, detailed description or any claim are followed by reference signs, the reference signs have been included to increase the intelligibility of the drawings, detailed description, and claims. Accordingly, neither the reference signs nor their absence have any limiting effect on the scope of any claim elements.

[0092] Modifications of described elements and acts such as variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, or orientations can occur without materially departing from the teachings and advantages of the subject matter disclosed herein. For example, elementsshown as integrally formed can be constructed of multiple parts or elements, the position of elements can be reversed or otherwise varied, and the nature or number of discrete elements or positions can be altered or varied. Other substitutions, modifications, changes and omissions can also be made in the design, operating conditions and arrangement of the disclosed elements and operations without departing from the scope of the present disclosure.[0093 | For example, descriptions of top and bottom, upper and lower, front and back, or left and right may be reversed or interchangeable. Elements described as negative elements can instead be configured as positive elements and elements described as positive elements can instead by configured as negative elements. For example, elements described as having first polarity can instead have a second polarity, and elements described as having a second polarity can instead have a first polarity. Further relative parallel, perpendicular, vertical or other positioning or orientation descriptions include variations within + / - 10% or + / -10 degrees of pure vertical, parallel or perpendicular positioning. References to “approximately,” “substantially” or other terms of degree include variations of + / - 10% from the given measurement, unit, or range unless explicitly indicated otherwise. Coupled elements can be electrically, mechanically, or physically coupled with one another directly or with intervening elements. Scope of the systems and methods described herein is thus indicated by the appended claims, rather than the foregoing description, and changes that come within the meaning and range of equivalency of the claims are embraced therein.

Claims

WHAT IS CLAIMED IS:

1. An anchoring device for a refractory material for lining a thermal vessel, the anchoring device comprising: a main body having an L-shape configured to extend at least partially around an edge of the thermal vessel, the main body comprising: a mounting element including a mounting surface and an outer surface; a first segment extending from the mounting element in a first direction, the first segment comprising a first segment outer surface and a first segment inner surface; and a second segment extending from the mounting element, the second segment comprising: a mounting portion extending in a second direction from the mounting element, the second direction opposite the first direction; an extension portion extending from the mounting portion in a third direction, the third direction different from the second direction; a second segment outer surface extending along the mounting portion and the extension portion; and a second segment inner surface extending along the mounting portion and the extension portion; wherein the outer surface, the first segment outer surface, and a section of the second segment outer surface form a planar outer surface; and wherein the mounting element, the first segment, and the second segment are disposed in a plane.

2. The anchoring device of claim 1, wherein the third direction is perpendicular to the second direction.

3. The anchoring device of claim 1, wherein the first segment inner surface, the mounting surface, and the second segment inner surface define a pocket to receive a stud.

4. The anchoring device of claim 3, wherein a depth of the mounting element is less than a maximum depth of the first segment and a maximum depth of the second segment.

5. The anchoring device of claim 3, wherein the mounting element comprises a recess configured to receive a first portion of the stud, and the mounting surface of the mounting element is configured to interface with a second portion of the stud, wherein the stud is disposed at least partially in the pocket.

6. The anchoring device of claim 1, wherein the mounting element is integrally formed with a stud, the stud configured to couple the anchoring device with the thermal vessel.

7. The anchoring device of claim 1, wherein the main body further comprises a plurality of voids, wherein the first segment comprises a first void of the plurality of voids and the second segment comprises a second void and a third void of the plurality of voids, the second void disposed on the mounting portion, and the third void disposed on the extension portion.

8. An anchoring device for a refractory material for lining a thermal vessel, the anchoring device comprising: a main body configured to extend at least partially around an edge of the thermal vessel, the main body comprising: a mounting element comprising an outer surface and a mounting surface; a first segment extending from the mounting element, the first segment comprising: a first mounting portion extending in a first direction from the mounting element; a first branch portion extending from the first mounting portion at an obtuse angle relative to the first mounting portion; and a first end portion extending from the first branch portion parallel with the first mounting portion; a second segment extending from the mounting element, the second segment comprising: a second mounting portion extending in a second direction from the mounting element, the second direction opposite the first direction, the second mounting portion comprising a bend;an extension portion extending from the first mounting portion in a third direction; a second branch portion extending from the extension portion at an obtuse angle relative to the extension portion; and a second end portion extending from the second branch portion parallel with the extension portion; wherein the mounting element, the first mounting portion, the second mounting portion, and the extension portion are disposed in a plane.

9. The anchoring device of claim 8, wherein: the first segment further comprises: a first segment outer surface extending along the first mounting portion, the first branch portion, and the first end portion; and a first segment inner surface extending along the first mounting portion, the first branch portion, and the first end portion; and the second segment further comprises: a second segment outer surface extending along the second mounting portion, the extension portion, the second branch portion, and the second end portion; and a second segment inner surface extending along the second mounting portion, the extension portion, the second branch portion, and the second end portion; wherein the outer surface, the first segment outer surface, and a portion of the second segment outer surface form a planar outer surface.

10. The anchoring device of claim 9, wherein the first segment inner surface, the mounting surface, and the second segment inner surface define a pocket to receive a stud.

11. The anchoring device of claim 10, wherein a depth of the mounting element is less than a maximum depth of the first segment and a maximum depth of the second segment.

12. The anchoring device of claim 10, wherein the mounting element comprises a recess configured to receive a first portion of the stud, and a second portion of the stud is configured tobe disposed at least partially in the pocket and interface with the inner mounting surface of the mounting element.

13. The anchoring device of claim 8, wherein the mounting element is integrally formed with a stud, the stud configured to couple the anchoring device with the thermal vessel.

14. The anchoring device of claim 8, wherein the plane is a first plane, wherein the first end portion and the second end portion are disposed in a second plane, the second plane offset from and parallel with the first plane.

15. The anchoring device of claim 8, wherein the third direction is perpendicular to the second direction.

16. The anchoring device of claim 8, wherein the main body further comprises a plurality of voids, the plurality of voids comprising: a first void disposed on the first branch portion; a second void disposed on the second mounting portion; and a third void disposed on the second branch portion.

17. An anchoring device for a refractory material for lining a thermal vessel, the anchoring device comprising: a main body configured to extend at least partially around an edge of the thermal vessel, the main body comprising: a mounting element comprising an outer surface and a mounting surface; a first segment extending from the mounting element, the first segment comprising: a first mounting portion extending in a first direction from the mounting element; a plurality of first branch portions extending from the first mounting portion at an obtuse angle relative to the first mounting portion; and a plurality of first end portions, each extending from a corresponding one of the plurality of first branch portions, the plurality of first end portions extending parallel with the first mounting portion;a second segment extending from the mounting element, the second segment comprising: a second mounting portion extending in a second direction from the mounting element, the second direction opposite the first direction, the second mounting portion comprising a bend; an extension portion extending from the first mounting portion in a third direction; a plurality of second branch portions extending from the extension portion at an obtuse angle relative to the extension portion; and a plurality of second end portions, each extending from a corresponding second branch portion of the plurality of second branch portions, the plurality of second end portions extending parallel with the extension portion; wherein the mounting element, the first mounting portion, the second mounting portion, and the extension portion are disposed in a plane.

18. The anchoring device of claim 17, wherein: the first segment further comprises: a first segment outer surface extending along the first mounting portion, the plurality of first branch portions, and the plurality of first end portions; and a first segment inner surface extending along the first mounting portion, the plurality of first branch portions, and the plurality of first end portions; and the second segment further comprises: a second segment outer surface extending along the second mounting portion, the extension portion, the plurality of second branch portions, and the plurality of second end portions; and a second segment inner surface extending along the second mounting portion, the extension portion, the plurality of second branch portions, and the plurality of second end portions; wherein the outer surface, the first segment outer surface, and a portion of the second segment outer surface form a planar outer surface.

19. The anchoring device of claim 18, wherein the first segment inner surface, the inner mounting surface, and the second segment inner surface define a pocket to receive a stud.

20. The anchoring device of claim 17, wherein the main body comprises a plurality of voids, the plurality of voids comprising: a first void that extends between a first branch portion of the plurality of first branch portions and a first end portion of the plurality of first end portions; a second void disposed on the second mounting portion; and a third void that extends between a second branch portion of the plurality of second branch portions and a second end portion of the plurality of second end portions.

Images