A masonry system, a masonry, a method of constructing a masonry and an aggregate for holding a molten metal

Abstract

The invention relates to a masonry system, a masonry, a method of constructing a masonry and an aggregate for holding a molten metal.

Description

[0001] A masonry system, a masonry, a method of constructing a masonry and an aggregate for holding a molten metal

[0002] D e s c r i p t i o n

[0003] The invention relates to a masonry system, a masonry, a method of constructing a masonry and an aggregate for holding a molten metal.

[0004] Aggregates for holding a molten metal are known, for example, in the form of blast furnaces, melting furnaces or casting machines. Such aggregate for holding a molten metal may comprise a tapping hole, also known as a tapping opening. Such a tapping hole is used to drain the molten metal, held in the aggregate, from the aggregate. The molten metal drained from the aggregate can, for example, be poured into molds or fed to further processing steps.

[0005] Often, the tapping hole is located in the lower area of an aggregate for holding a molten metal. The tapping hole is usually designed as an opening that is surrounded by a masonry of refractory bricks. When holding a molten metal in the aggregate, the tapping hole is closed, usually by refractory material. To open the tapping hole, the refractory material by which the tapping hole is closed is broken out of the tapping hole so that molten metal can be discharged from the tapping hole in a controlled manner. Afterwards, the tapping hole may be closed again by refractory material. The masonry in the region of a tapping hole is exposed to strong mechanical stress and corrosive attack from the molten metal. Particularly when molten metal is flowing through the tapping hole, the masonry in the region of the tapping hole is exposed to strong corrosive attack by the molten metal. In order to withstand this strong mechanical and corrosive attack by the molten metal, the masonry in the region of a tapping hole is regularly made of refractory bricks which are mortared together. However, the stability of the masonry can be negatively affected by progressive corrosion of the masonry. If the wear of the masonry exceeds a certain level, the stability of the masonry in the region of a tapping hole can no longer be guaranteed with the masonries known from the state of the art.

[0006] It is an object of the present invention to provide a masonry system which is configured to construct a masonry in the region of a tapping hole of an aggregate for holding a molten metal, which masonry still offers good stability even with advanced corrosion of the refractory bricks of the masonry, in particular better stability than the masonries known from the state of the art.

[0007] It is a further object of the present invention to provide a masonry system that further allows quick and easy construction and repair of a masonry in the region of a tapping hole of an aggregate for holding the molten metal, in particular even during operation of the aggregate.

[0008] To solve this problem, the invention provides a masonry system configured to construct a masonry in the region of the tapping hole of an aggregate for holding a molten metal, the masonry system comprising: refractory bricks; said refractory bricks comprise refractory bricks which can be arranged side by side such that they form a common first side; said refractory bricks comprise refractory bricks which can be arranged side by side such that they form a common second side; said common first side comprises a first surface and at least one protrusion protruding from said first surface; said common second side comprises a second surface and at least one recess that recedes from said second surface; wherein said common first side and said common second side are contactable with one other to form a contact area such that said common first side contacts said common second side; and wherein said common first side and said common second side are configured such that, upon formation of said contact area, said at least one protrusion is at least partially engaged in said at least one recess, forming a form-fit connection.

[0009] Surprisingly, it has been found in the context of the invention that a masonry system according to the invention allows providing a masonry in the region of a tapping hole that still ensures a high stability even with advanced corrosion of the refractory bricks of the masonry, in particular a higher stability than with the masonries known from the state of the art.

[0010] Further, it has been found that the masonry system according to the invention allows quick and easy construction and repair of a masonry in the region of a tapping hole of an aggregate for holding the molten metal, in particular even during operation of the aggregate.

[0011] According to the invention, the form-fit connection, i.e. , the positive connection, is formed upon formation of said contact area, i.e., when the common first side contacts the common second side of the refractory bricks such that said at least one protrusion of the common first side is at least partially engaged in said at least one recess of the common second side.

[0012] Consequently, by the form-fit connection according to the invention, the refractory bricks forming the first side and the refractory bricks forming the second side are connected to each other.

[0013] According to a particularly preferred embodiment, it may be provided that the common second side is complementary to the common first side. In other words, the common second side has a surface geometry or topography that is the negative of the surface geometry or topography of the common first side.

[0014] This embodiment also has the particular advantage that, when the contact area is formed with the common second side, the common first side may be in essentially full-surface contact with the common second side, whereby not only a secure form-fit connection can be formed, but penetration of molten metal into the contact area can also be suppressed at the same time. The masonry system according to the present invention comprises refractory bricks which can be arranged side by side such that they form a common first side. In other words, the masonry system comprises refractory bricks which can be arranged side by side such that, when so arranged side by side, the refractory bricks form a common side towards one side, referred to herein as the "common first side". Preferably, this common first side is a continuous common first side. Preferably, the refractory bricks, which can be arranged side by side such that they form a common first side, are therefore designed such that they can be arranged side by side to form a common first side. According to a preferred embodiment, the refractory bricks, which can be arranged side by side such that they form a common first side, have flat side surfaces facing each other, with which they can be arranged side by side. The refractory bricks can make full-surface contact with each other via these flat side surfaces if the refractory bricks are arranged side by side. This makes it particularly easy to construct a tight brickwork that can prevent the penetration of molten metal. The refractory bricks of the masonry system according to the invention, which can be arranged side by side such that they form a common first side, can preferably have an essentially cuboidal basic structure. As a result, these refractory bricks can be arranged particularly easily in such a way that they form both, a common first side and at the same time have flat side surfaces with which they can make full-surface contact with one another when the refractory bricks are arranged side by side.

[0015] According to the invention, the masonry system according to the present invention comprises refractory bricks which can be arranged side by side such that they form a common second side. In other words, the masonry system comprises refractory bricks which can be arranged side by side such that, when so arranged side by side, the refractory bricks form a common side towards one side, referred to herein as the "common second side". Preferably, this common second side is a continuous common second side. Preferably, the refractory bricks, which can be arranged side by side such that they form a common second side, are therefore designed such that they can be arranged side by side to form a common second side. According to a preferred embodiment, the refractory bricks, which can be arranged side by side such that they form a common second side, have flat side surfaces facing each other, with which they can be arranged side by side. The refractory bricks can make full- surface contact with each other via these flat side surfaces if the refractory bricks are arranged side by side. This makes it particularly easy to construct a tight brickwork that can prevent the penetration of molten metal. The refractory bricks of the masonry system according to the invention, which can be arranged side by side such that they form a common second side, can preferably have an essentially cuboidal basic structure. As a result, these refractory bricks can be arranged particularly easily in such a way that they form both, a common second side and at the same time have flat side surfaces with which they can make full-surface contact with one another when the refractory bricks are arranged side by side.

[0016] According to one embodiment, it may be provided that the first surface of the common first side and the second surface of the common second side are essentially flat, i.e., planar, so that they can easily complement each other over their entire surface particularly easily and effectively when the contact area is formed between the common first side and common second side.

[0017] According to a preferred embodiment, the form-fit connection acts parallel to the first and second surface of the common first and second side forming the contact area. In other words, the form-fit connection prevents any relative movement between the first and second surface parallel to the first and second surface.

[0018] The forces acting on the masonry by the molten metal in the region of a tapping hole also act in one direction in particular, namely, in particular also perpendicular to the surface of the masonry facing the molten metal. In order to counteract these forces, it may be sufficient to design the masonry system according to the invention in such a way that the form-fit connection acts at least in one direction, namely, in particular in the direction of the forces acting on the masonry in the normal direction due to the molten metal.

[0019] As a further development of this inventive concept, it may be provided that the form-fit connection acts in at least one direction parallel to the first and second surface of the common first and second side forming the contact area. In this embodiment, the form-fit connection therefore prevents any relative movement between the first and second surfaces along at least one direction parallel to the first and second surface.

[0020] However, forces can act not only in the normal direction, but also parallel to the surface of the masonry (e.g., as shear forces), particularly in the case of strong flow movements of the melt in the area of the tapping hole. In this case, forces therefore act on the masonry in several directions.

[0021] According to one embodiment, it may therefore be provided that the form-fit connection acts in all directions parallel to the first and second surface.

[0022] By forming a corresponding form-fit connection, a form-fit connection can therefore be provided in the entire plane of the first and second surface of the common first and second side forming the contact area.

[0023] In this embodiment, the form-fit connection therefore acts in all directions parallel to the first and second surface, so that the refractory bricks have no degree of freedom of movement in any direction along this plane.

[0024] According to a preferred embodiment, it may be provided that the masonry system is configured such that a plurality of said contact areas can be formed.

[0025] In this embodiment, the masonry that can be constructed using the masonry system according to the invention can still have particularly good stability in the area of the tapping hole, even with advanced corrosion of the refractory bricks.

[0026] In order to construct such masonry from the masonry system according to the invention, it can preferably be provided that a plurality of contact areas as described herein can be formed between several layers of refractory bricks, in particular several successive layers of refractory bricks in a masonry that can be constructed from the masonry system according to the invention. In order to achieve this, according to a particularly preferred embodiment, it may be provided that the refractory bricks of the masonry system according to the present invention comprise refractory bricks which can be arranged side by side such that they form both, a common first side and a common second side. According to a particularly preferred embodiment, it may be provided that the refractory bricks of the masonry system according to the present invention comprise refractory bricks which can be arranged side by side such that they form both, a common first side and an opposite common second side. This makes it particularly easy to construct a masonry of a desired size or extension.

[0027] According to one embodiment, it may be provided that the common first side is bounded by four side edges forming the outline of a quadrilateral, the four side edges comprising a first side edge and a second side edge opposite the first side edge, and a third side edge and a fourth side edge opposite the third side edge.

[0028] A masonry system according to the invention, which comprises refractory bricks having a correspondingly formed common first side, is particularly easy to form if the refractory bricks have a substantially cuboidal structure, as explained above.

[0029] The geometry or shape of the refractory bricks, which can be arranged side by side such that they form the common first side, is such that they define the geometry or shape of the common first side. In this respect, the individual geometry or shape of these refractory bricks "complements" each other to the geometry or shape of the common first side.

[0030] According to a preferred embodiment, it may be provided that the at least one protrusion comprises a first protrusion extending along a first direction from the first side edge to the second side edge of the common first side.

[0031] In other words, in this embodiment, the first protrusion extends over the entire length of the common first side from the first side edge to the opposite second side edge of the common first side. By means of such a protrusion, the form-fit connection can be formed very simply and effectively, in particular in such a way that it acts at least in a direction parallel to the first and second surfaces, in particular in a direction normal to the first direction along which the first protrusion extends.

[0032] As explained above, the common second side can preferably be complementary to the common first side.

[0033] According to one embodiment, it may therefore be provided that the common second side is bounded by four side edges forming the outline of a quadrilateral, the four side edges comprising a first side edge and a second side edge opposite the first side edge, and a third side edge and a fourth side edge opposite the third side edge.

[0034] The geometry or shape of the refractory bricks, which can be arranged side by side such that they form the common second side, is such that they define the geometry or shape of the common second side. In this respect, the individual geometry or shape of these refractory bricks "complements" each other to the geometry or shape of the common second side.

[0035] According to a further embodiment of this inventive concept, the at least one recess comprises a first recess extending along a first direction from the first side edge to the second side edge of the common second side.

[0036] This first recess can preferably be formed complementary to the first protrusion, so that the first protrusion can be positively engaged in the first recess.

[0037] According to one embodiment, it may be provided that the cross-sectional area of the first protrusion, with a sectional plane perpendicular to the first direction, does not change along the first direction.

[0038] According to a preferred embodiment, the first protrusion can have a rectangular outer contour. The advantage of such a rectangular outer contour of the first protrusion is in particular also that it can be combined with first protrusion of adjacent refractory bricks to form an "endless" protrusion with a continuously identical contour, which particularly facilitates the arrangement of refractory bricks of the masonry system according to the invention next to each other.

[0039] According to a preferred embodiment, it may be provided that the at least one protrusion comprises at least one second protrusion extending along a second direction from the third side edge to the fourth side edge of the common first side.

[0040] In other words, the at least one second protrusion extends over the entire length of the first side from the third side edge to the opposite fourth side edge of the common first side.

[0041] According to a particularly preferred embodiment, the common first side comprises both the first protrusion and the at least one second protrusion. This has the particular advantage that a form-fit connection can be formed particularly easily and effectively, which acts in all directions parallel to the first and second surface when they form the contact area. This is because the first protrusion and the at least one second protrusion can each form a form-fit connection that acts in a different direction, so that the simultaneous presence of the first protrusion and the at least one second protrusion allows a form-fit connection to be formed in one plane. In this plane, i.e. , in the plane parallel to the first and second surfaces, the masonry that can be constructed from the masonry system according to the invention, is therefore particularly stable.

[0042] According to a preferred embodiment, the first direction, along which the first protrusion extends, and the second direction, along which the at least one second protrusion extends, preferably run at right angles to each other. As a result, a form-fit connection can be formed particularly effectively in the entire plane parallel to the first and second surface.

[0043] As explained above, the common second side can preferably be complementary to the common first side. According to one embodiment, it may therefore be provided that the at least one recess comprises a second recess which extends along a second direction from the third side edge to the fourth side edge of the common second side. This second recess can be formed complementary to the second protrusion, so that the second protrusion can in turn be form-fit engaged in the second recess. Insofar as the common first side of the refractory brick has both the first protrusion and the at least one second protrusion, these protrusions can complement each other excellently, in particular synergistically, in a masonry which can be constructed from the masonry system according to the invention. This is because while the first protrusion can preferably in particular absorb forces which act in the normal direction to the surface of the masonry, i.e. , in particular in the normal direction from the molten metal to the masonry, the at least one second protrusion can in particular absorb forces which do not act in the normal direction to the masonry, i.e. for example shear forces which act on the masonry at an angle or also parallel to the surface of the masonry.

[0044] According to one particularly preferred embodiment, it may be provided that the cross- sectional area of the at least one second protrusion, with a sectional plane perpendicular to the second direction, changes along the second direction.

[0045] It was surprisingly recognized that the stability of a masonry that can be constructed from the masonry system according to the invention can continue to be ensured by means of a correspondingly formed second protrusion even if the masonry is so heavily corroded by a corrosion attack of the molten material that the first protrusion is completely corroded. This is because, due to the change in the cross-sectional area of the second protrusion, the refractory bricks can still be prevented from shifting or slipping along the second direction even if the form-fit connection by the first protrusion is no longer effective.

[0046] According to a further embodiment of this inventive concept, it may be provided that the cross-sectional area of the at least one second protrusion changes along the second direction to the extent that the cross-sectional area decreases from the third outer edge to the fourth outer edge of the common second side, wherein according to a further embodiment of this inventive concept it may further be provided that the third outer edge in the masonry which can be constructed from the masonry system according to the invention represents the outer edge which faces the molten metal in the aggregate. According to a preferred embodiment, the cross-sectional area of the at least one second protrusion changes continuously, and in particular decreases continuously from the third side edge to the fourth side edge of the common first side.

[0047] According to a further development of this idea of the invention, the cross-sectional area of the at least one second protrusion decreases in particular continuously from the third outer edge to the fourth outer edge of the common first side, wherein the third outer edge in the masonry which can be erected from the masonry system according to the invention represents the outer edge which faces the molten metal in the aggregate.

[0048] According to a preferred embodiment, it may be provided that the at least one second protrusion has a wedge-shaped outer contour.

[0049] A second protrusion with such a wedge-shaped outer contour represents a particularly easy- to-produce embodiment of a second protrusion, the cross-sectional area of which changes continuously. Preferably, it can be provided that the wedge-shaped contour tapers from the third outer edge to the fourth outer edge of the first side, the third outer edge preferably representing the outer edge facing the molten metal in the aggregate in the masonry that can be constructed from the masonry system according to the invention.

[0050] According to a preferred embodiment, it may be provided that the at least one protrusion on the common first side has at least two protrusions, each of which is formed in accordance with the second protrusion described herein. In particular, this embodiment also has the particular advantage that the stability of the masonry which can be constructed from the masonry system according to the invention can continue to be ensured even if such a refractory brick breaks. Then, if the refractory brick should break between the two second protrusions, each part of the refractory brick which has such a second protrusion can continue to form a secure connection with the adjacent refractory brick in the complementary recesses of which it is engaged.

[0051] According to the invention, it was found that the height of the protrusions, i.e., the height at which the protrusions rise above the surface of the common first side, has an influence on the properties of the masonry that can be constructed from the masonry system according to the invention. In this respect, it was found that the protrusions can break off if they are too high, in particular if they are higher than 30 mm. It was also found that the form-fit connection may not be strong enough if the height is too low, in particular if it is less than 5 mm. According to a preferred embodiment, it can therefore be provided that the protrusions have a height in the range from 5 to 30 mm, particularly preferably in the range from 10 to 15 mm. Preferably, the at least one first protrusion and the at least one second protrusion each have the same height.

[0052] Preferably, the first protrusion extends at a distance from both the third and the fourth side edge of the common first side. According to the invention, it was found that, when forming the form-fit connection, the force absorbed by the refractory bricks can thus be transferred very evenly to the bricks without overloading one side of the refractory bricks.

[0053] The second protrusion preferably extends at a distance from both the first and the second side edge of the common first side. This also allows the force absorbed by the respective refractory bricks when forming the form-fit connection to be transferred evenly to the refractory bricks without overloading one side of the refractory bricks.

[0054] Insofar as the common first side has a plurality of second protrusions, as stated herein, these second protrusions preferably extend at a distance from the first and second side edges and at a distance from one another.

[0055] The respective surfaces of the common first side and the common second side are preferably flat, i.e. , even. This makes it particularly easy to form a full-surface contact between adjacent refractory bricks, which creates a particularly good form-fit connection and prevents molten metal from penetrating into the contact area.

[0056] Insofar as the refractory bricks of the masonry system according to the invention preferably have both at least one first and at least one second protrusion on the common first side, as set forth herein, these first and second protrusions can preferably intersect or overlap. Furthermore, as the first and second protrusion have the same height, as explained herein, they can form a common surface in the area of their overlap.

[0057] According to the invention, it was found that the shape of the flanks of the protrusions, i.e. their sides or slopes with which they slope down onto the common first side, can have an influence on the form-fit connection. In this respect, it was found that a flank that falls at a right angle to the surface of the first side can be easily damaged, especially when erecting the masonry. However, if the angle of the flank is too big, the refractory bricks can easily detach from the form-fit connection and slip against each other, especially at an angle greater than 150°. The angle is defined as the angle that the flank of the protrusion and the surface of the common first side enclose towards the outside. According to a preferred embodiment, it can therefore be provided that the flanks of the protrusions slope at an angle > 90° towards the surface of the common first side. Particularly preferably, the flanks of the protrusions slope at an angle in the range of 100 to 150° towards the surface of the common first side.

[0058] According to the invention, it was found that the size of the surface area of the first and second protrusions, which they occupy from the common first side, can have an influence on the positive connection. This is because, if the surface area is very small, the strength of the protrusions may not be sufficient to ensure a good connection of the masonry. However, if it is very large, the strength of the remaining refractory brick material next to the recesses on the common second side can be so low that the brick can break. It may therefore be preferable for the protrusions on the common first side to occupy an area in the range from 10 to 90%, particularly preferably in the range from 20 to 80% of the area of the common first side.

[0059] The refractory bricks of the masonry system according to the invention can basically consist of any material known for refractory bricks in the area of a tapping hole. Preferably, the refractory bricks consist of a ceramic material, particularly preferable of a sintered ceramic material. Preferably, the refractory bricks consist of a sintered ceramic material based on at least one metal oxide. Preferably, the refractory bricks consist of a sintered ceramic material based on at least one of the following metal oxides: magnesia (MgO) and alumina (AI2O3). Alternatively, the refractory bricks may be carbon bond, for example may be made from magnesia-carbon (MgO-C) material. For example, the refractory bricks may be present in the form of at least one of the following refractory brick types: alumina bricks, high-alumina bricks, magnesia bricks, magnesia-chromite bricks, alumina-chromite bricks, and magnesia- carbon bricks.

[0060] Another subject of the invention is a refractory brick formed as disclosed herein.

[0061] Subject of the invention is also a masonry in the region of the tapping hole of an aggregate for holding a molten metal, wherein the masonry is constructed from a masonry system according to the present invention.

[0062] In this respect, the masonry according to the invention comprises the refractory bricks of the masonry system according to the invention disclosed herein.

[0063] Accordingly, the masonry according to the invention comprises the refractory bricks of the masonry system of the present invention, wherein said refractory bricks comprise refractory bricks which are arranged side by side such that they form a common first side; said refractory bricks comprise refractory bricks which are arranged side by side such that they form a common second side; said common first side comprises a first surface and at least one protrusion protruding from said common first surface; said common second side comprises a second surface and at least one recess that recedes from said common second surface; wherein said common first side and said common second side are contacted with one other to form a contact area such that said common first side contacts said common second side; and wherein said common first side and said common second side are configured such that, in said formed contact area, said at least one protrusion is at least partially engaged in said at least one recess, forming a form-fit connection. Subject of the invention is also a method of constructing a masonry in the region of the tapping hole of an aggregate for holding a molten metal, the method comprising the following steps: providing a masonry system according to the present invention; contacting the refractory bricks to form the contact area.

[0064] In particular, the masonry according to the invention can be constructed using the method according to the invention.

[0065] Subject of the invention is also an aggregate for holding a molten metal, the aggregate comprising: a tapping hole; and a masonry in the region of the tapping hole; wherein the masonry is constructed from a masonry system according to the present invention.

[0066] The aggregate according to the invention can preferably be at least one of the following aggregates, as described above: blast furnace, melting furnace or casting machine.

[0067] Further features of the invention are apparent from the claims, the figures, and the associated description of the figures.

[0068] All features of the invention can be combined with each other, individually or in combination, as desired.

[0069] Exemplary embodiments of the invention are explained in more detail in the figures and the following description of the figures. In the figures, the following is illustrated:

[0070] Figure 1 a first section of a first exemplary embodiment of a masonry system in accordance with the present invention in a perspective view from diagonally above; Figure 2 a second section of the first exemplary embodiment of a masonry system according to Figure 1 in a perspective view from diagonally above;

[0071] Figure 3 a perspective view from diagonally above of a first type of refractory brick of the masonry system according to Figures 1 and 2;

[0072] Figure 4 a perspective view from above of the type of refractory brick shown in Figure 3 in a different orientation of the refractory brick;

[0073] Figure 5 a perspective view from above of the type of refractory brick shown in Figure 3, with non-visible edges shown in dashed lines;

[0074] Figure 6 a top view of the type of refractory brick shown in Figure 3;

[0075] Figure 7 a side view of the type of refractory brick shown in Figure 3;

[0076] Figure 8 a perspective view from diagonally above of a second type of refractory brick of the masonry system according to Figures 1 and 2;

[0077] Figure 9 a perspective view from diagonally above of the type of refractory brick shown in Figure 8 in a different orientation of the refractory brick;

[0078] Figure 10 a perspective view from above of the type of refractory brick shown in Figure 8, with non-visible edges shown in dashed lines;

[0079] Figure 11 a masonry in the region of the tapping hole of an aggregate for holding a molten metal, the masonry comprising an exemplary embodiment of a masonry in accordance with the present invention in a perspective view from diagonally above;

[0080] Figure 12 the masonry according to Figure 11 , but with closed tapping hole; Figure 13 a first section of a second exemplary embodiment of a masonry system in accordance with the present invention in a perspective view from diagonally above; and

[0081] Figure 14 a second section of the second exemplary embodiment of a masonry system according to Figure 13 in a perspective view from diagonally above.

[0082] Figures 1 and 2 show sections 1 , 100 of an exemplary embodiment of a masonry system according to the invention. These sections 1 , 100 can be combined to form a single exemplary embodiment of a masonry system according to the invention. For the sake of clarity, the two sections 1, 100 are illustrated separately.

[0083] The first section 1 of the embodiment of the masonry system according to Figure 1 comprises refractory bricks arranged in four layers 2, 3, 4, 5 one above the other. In each of the layers 2, 3, 4, 5, two refractory bricks are arranged next to each other, side by side. These two refractory bricks arranged side by side in the uppermost layer 5 are marked with the reference signs 6 and 7 in Figure 1 .

[0084] The refractory bricks 6, 7 are arranged side by side in such a way that they form a common first side 8. This common first side 8 is a continuous common first side 8. To achieve this, the refractory bricks 6, 7 are, as explained in detail below, designed such that they can be arranged side by side to form the common first side 8. The common first side 8 is bounded by four side edges forming the outline of a quadrilateral, the four side edges comprising a first side edge 9 and a second side edge 10 opposite the first side edge 9, and a third side edge 11 and a fourth side edge 12 opposite the third side edge 11. The common first side 8 comprises a first surface 22 and a plurality of protrusions 13, 14, 15, 16, protruding from said first surface 22. The first surface 22 is essentially flat, i.e. , planar. The protrusions 13, 14, 15, 16 comprise a first protrusion 13 and three second protrusions 14, 15, 16. The first protrusion 13 extends along a first direction 18 from the first side edge 9 to the second side edge 10, wherein the cross-sectional area of the first protrusion 13, with a sectional plane perpendicular to the first direction 18, does not change along the first direction 18. Insofar, the first protrusion 13 shows a rectangular outer contour. The three second protrusions 14, 15, 16 each extend along a respective second direction 19, 20, 21 from the third side edge 11 to the fourth side edge 12, wherein the cross-sectional area of the respective second protrusion 14, 15, 16, with a sectional plane perpendicular to the respective second direction 19, 20, 21 increases continuously along the respective second direction 19, 20, 21. Accordingly, each second protrusion 14, 15, 16 has a wedge-shaped outer contour. Further, the shape of each of the second protrusions 14, 15, 16 is identical. The first protrusion 14 extends at a distance from both the third side edge 11 and the fourth side edge 12. Further, the second protrusions 14, 15, 16 each extend at a distance from the first side edge 9 and second side edge 10 and at a distance from one another. Accordingly, the first protrusion 13 intersects with each of the second protrusions 14, 15, 16.

[0085] Each protrusion 13, 14, 15, 16 has the same height of 15 mm above the first surface 22. As each protrusion 13, 14, 15, 16 has the same height and as the first protrusion 13 intersects with each of the second protrusions 14, 15, 16, the protrusions 13, 14, 15, 16 form a common surface in the area of their intersection or overlap.

[0086] The flanks 211 of the protrusions 13, 14, 15, 16 and the first surface 22 enclose an angle of 135°.

[0087] The second section 100 of the embodiment of the masonry system according to Figure 2 comprises refractory bricks arranged in four layers 101 , 102, 103, 104 one above the other. In each of the layers 101, 102, 103, 104, two refractory bricks are arranged next to each other, side by side. These two refractory bricks of the uppermost layer 104, arranged side by side, are identified in Figure 2 by the reference signs 105 and 106.

[0088] The refractory bricks 105, 106 are arranged side by side in such a way that they form a common second side 107. This common second side 107 is a continuous common second side 107. To achieve this, the refractory bricks 105, 106 are, as further detailed below, designed such that they can be arranged side by side without joints to form the common second side 107. The common second side 107 is bounded by four side edges forming the outline of a quadrilateral, the four side edges comprising a first side edge 108 and a second side edge 109 opposite the first side edge 108, and a third side edge 110 and a fourth side edge 111 opposite the third side edge 110. The common second side 107 comprises a second surface 112 and a plurality of recesses 113, 114, 115, 116, receding from said second surface 112. The second surface 112 is essentially flat, i.e., planar. The recesses 113, 114, 115, 116 comprise a first recess 113 and three second recesses 114, 115, 116. The first recess 113 extends along a first direction 117 from the first side edge 108 to the second side edge 109. The three second recesses 114, 115, 116 each extend along a second direction 118, 119, 120 from the third side edge 110 to the fourth side edge 111.

[0089] The common second side 107 is complementary to the common first side 8. Accordingly, the common second side 107 has a topography that is the negative of the topography of the common first side 8. Since the topography of the common second side 107 is insofar the negative of the topography of the common first side 8, said common first side 8 and said common second side 107 are contactable with one another to form a contact area such that said common first side 8 contacts said common second side 107 and wherein, upon formation of said contact area, the protrusions 13, 14, 15, 16 are fully engaged in the recesses 113, 114, 115, 116, forming a form-fit connection between the refractory bricks 6, 7 on the one hand and the refractory bricks 105, 106 on the other hand. In detail, when forming such form-fit connection, the first surface 22 lies on the second surface 112, the first protrusion 13 is positively engaged in the first recess 113, and the three second protrusions 14, 15, 16 are positively engaged in the second recesses 114, 115, 116.

[0090] In order to produce this form-fit connection, the first section 1 is to be placed with the common first side 8 on the common second side 107 of the second section 100, so that the aforementioned contact area is formed between them.

[0091] From the shape of the protrusions 13, 14, 15, 16 according to the embodiment and their form-fit connection, it follows that the form-fit connection acts in all directions parallel to the first surface 22 and second surface 112.

[0092] The refractory bricks 6, 7 are therefore positively connected to the refractory bricks 105, 106.

[0093] The refractory bricks 6, 7, 105, 106 are shown in more detail in Figures 3-10. In this respect, the sections 1, 100 of the masonry system consist of only two different types of refractory bricks, namely a first type of refractory brick 200 and a second type of refractory brick 300. The refractory bricks 6 and 105 correspond to the first type of refractory brick 200 and the bricks 7 and 106 correspond to the second type of refractory brick 300.

[0094] The refractory bricks 200, 300 of the first and second type each have an essentially cuboidal basic structure with flat side surfaces 201-204; 301-304 so that they can be arranged side by side such that they form the common first side 8 and the common second side 107. Due to their flat surfaces 201-204; 301-304, the refractory bricks 200, 300 can make full-surface contact with each other.

[0095] Further, the refractory bricks 200, 300 are designed in a way that they can be arranged side by side such that they form both, the common first side 8 and opposite the common second side 107. For this purpose, the refractory bricks 200, 300 have opposite sides 205, 206; 305, 306 which are shaped complementary to each other. Thus, the first type of refractory brick 200 has a side 205 and an opposite side 206, wherein the side 206 is shaped complementary to the side 205. In this respect, side 206 is the negative of side 205.

[0096] Similarly, the second type of refractory brick 300 has a side 305 and an opposite side 306, wherein the side 306 is shaped complementary to side 305, so that side 306 is again the negative of side 305. The refractory bricks 200, 300 can now be arranged next to one another via their flat side surfaces 201 , 203; 301 , 303 in such a way that their sides 205, 305 together form the common first side 8 and at the same time their sides 206, 306 together form the common second side 107.

[0097] The refractory brick 200 of the first type has a protrusion 208 on its side 205 and the refractory brick 300 of the second type has a protrusion 308 on its side 305. In the case of the bricks 200, 300 lying side by side in one layer, these projections 208, 308 together form the first protrusion 13.

[0098] Furthermore, the refractory brick 200 of the first type has a protrusion 207 on its side 205 and the refractory brick 300 of the second type has two protrusions 307 on its side 305. In the case of the bricks 200, 300 lying side by side in one layer, these protrusions 207, 307 form the second protrusions 14, 15, 16.

[0099] The refractory brick 200 of the first type has a recess 210 on its side 206 opposite the side 205 and the refractory brick 300 of the second type has a recess 310 on its side 306 opposite the side 305. In the case of the bricks 200, 300 lying side by side in one layer, these recesses 210, 310 together form the first recess 113.

[0100] Furthermore, the refractory brick 200 of the first type has a recess 209 on its side 206 and the refractory brick 300 of the second type has two recesses 309 on its side 306. In the case of the bricks 200, 300 lying side by side in one layer, these recesses 209, 309 form the second recesses 114, 115, 116.

[0101] This makes it possible to provide a masonry system by means of the refractory bricks 200, 300, by means of which any number of directly successive layers of refractory bricks are arranged within the masonry, between which contact areas according to the invention are formed in each case.

[0102] Thus, in the exemplary embodiment, each of the layers 2, 3, 4 of the first section 1 comprises the two refractory bricks 200, 300, wherein a contact area according to the invention is formed between each of the layers 2, 3, 4, so that the refractory bricks 200, 300 are form-fit connected to each other between the layers 2, 3, 4.

[0103] This applies correspondingly in the same way to each of the layers 102, 103, 104 of the second section 100, which also each comprise the two refractory bricks 200, 300, and wherein a contact area according to the invention is also formed between each of the layers 102, 103, 104, so that the refractory bricks 200, 300 between the layers 102, 103, 104 are each form-fit connected to one another.

[0104] The two types of refractory bricks 200, 300 are designed in such a way that their contact is offset from layer to layer via the flat side surfaces 201 , 203; 301 , 303, which gives the masonry additional stability. Figure 7, which shows a frontal view onto the side 201 of the refractory brick 200 of the first type, shows that the flanks 211 slope at an angle 212 of 135°.

[0105] Each of the refractory bricks 200, 300 is made from sintered ceramic material based on alumina (AI2O3) and thus the refractory bricks 200, 300 are present in the form of alumina bricks.

[0106] Figures 11 , 12 show a masonry 400 in the region of the tapping hole 401 of an aggregate for holding a molten metal, the masonry 400 comprising an exemplary embodiment of a masonry 402 in accordance with the present invention. The tapping hole 401 is bordered at the top and sides by the exemplary embodiment of a masonry 402 in accordance with the present invention. The masonry 402 is in turn bordered on the outside by a masonry 403 in accordance with the prior art.

[0107] In Figure 11 , the tapping hole 401 is open, while in Figure 12 it is closed by refractory material 404.

[0108] The masonry 400 is part of an aggregate for holding a molten metal.

[0109] Figures 13, 14 show a second example of a masonry system according to the invention. In principle, this system corresponds to the system shown in Figures 1 to 10, although the refractory bricks are of an alternative design.

Claims

A masonry system, a masonry, a method of constructing a masonry and an aggregate for receiving a molten metalC l a i m s1 . A masonry system configured to construct a masonry (402) in the region of the tapping hole (401) of an aggregate for holding a molten metal, the masonry system comprising:1.1 refractory bricks (6, 7; 105, 106);1.2 said refractory bricks (6, 7; 105, 106) comprise refractory bricks (6, 7) which can be arranged side by side such that they form a common first side (8);1.3 said refractory bricks (6, 7; 105, 106) comprise refractory bricks (105, 106) which can be arranged side by side such that they form a common second side (107);1.4 said common first side (8) comprises a first surface (22) and at least one protrusion (13, 14, 15, 16) protruding from said first surface (22);1.5 said common second side (107) comprises a second surface (112) and at least one recess (113, 114, 115, 116) that recedes from said second surface (112); wherein1.6 said common first side (8) and said common second side (107) are contactable with one other to form a contact area such that said common first side (8) contacts said common second side (107); wherein1.7 said common first side (8) and said common second side (107) are configured such that, upon formation of said contact area, said at least one protrusion (13, 14, 15, 16) is at least partially engaged in said at least one recess (113, 114, 115, 116), forming a form-fit connection; wherein1.8 said common first (8) side is bounded by four side edges (9, 10, 11 , 12) forming the outline of a quadrilateral, the four side edges comprising a first side edge (9) and a second side edge (10) opposite the first side edge (9), and a third side edge (11) and a fourth side edge (12) opposite the third side edge (11); wherein1.9 the at least one protrusion (13, 14, 15, 16) comprises a first protrusion (13) extending along a first direction (18) from the first side edge (9) to the second side edge (10) of said common first side (8); wherein1.10 the at least one protrusion (13, 14, 15, 16) comprises at least one second protrusion (14, 15, 16) extending along a second direction (19, 20, 21) from the third side edge (11) to the fourth side edge (12) of the common first side (8); and wherein1.11 the cross-sectional area of the at least one second protrusion (14, 15, 16), with a sectional plane perpendicular to the second direction (19, 20, 21), changes along the second direction (19, 20, 21).

2. The masonry system according to claim 1 , wherein the form-fit connection acts parallel to the first surface (22) and the second surface (112).

3. The masonry system according to at least one of the preceding claims, wherein the form-fit connection acts in all directions parallel to the first surface (22) and the second surface (112).

4. The masonry system according to at least one of the preceding claims, wherein the masonry system is configured such that a plurality of said contact areas can be formed.

5. The masonry system according to at least one of the preceding claims, wherein said refractory bricks (6, 7; 105, 106) comprise refractory bricks (6, 7; 105, 106) which can be arranged side by side such that they form both, a common first side (8) and a common second side (107).

6. The masonry system according to at least one of the preceding claims, wherein the cross-sectional area of the first protrusion (13), with a sectional plane perpendicular to the first direction (18), does not change along the first direction (18).

7. The masonry system according to at least one of the preceding claims, wherein the cross-sectional area of the second protrusion, with a sectional plane perpendicular to thesecond direction (19, 20, 21), increases continuously along the second direction (19, 20, 21).

8. The masonry system according to at least one of the preceding claims, wherein the at least one second protrusion (14, 15, 16) has a wedge-shaped outer contour.

9. A masonry (402) in the region of the tapping hole (401) of an aggregate for receiving a molten metal, wherein the masonry (402) is constructed from a masonry system according to at least one of the preceding claims.

10. A method of constructing a masonry (402) in the region of the tapping hole (401) of an aggregate for holding a molten metal, the method comprising the following steps:A. providing a masonry system according to at least one of claims 1 to 8;B. contacting the refractory bricks (6, 7; 105, 106) to form the contact area.

11. An aggregate for receiving a molten metal, the aggregate comprising:11.1 atapping hole (401); and11.2 a masonry (402) in the region of the tapping hole (401); wherein11.3 the masonry (402) is constructed from a masonry system according to at least one of claims 1 to 8.

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