furnace panel

Abstract

The invention relates to a panel (300) intended for monitoring a refractory component of a furnace, comprising: - a support plate (310) through which a plurality of orifices (304) pass and which is at least partially made of a material consisting of fibers interconnected by a ceramic matrix, called "ceramic-matrix composite material", or consisting of a precursor of said ceramic-matrix composite material; - a sensor (312) carried by said support plate, the precursor of the ceramic-matrix composite material being a material that can be transformed into said ceramic-matrix composite material under the action of heating.

Description

Technical Field

[0001] The present invention relates to an instrument panel intended for monitoring refractory components of furnaces, particularly metallurgical furnaces or glass furnaces, and especially for determining the appropriate time for furnace repair or shutdown.

[0002] The present invention also relates to a furnace comprising a refractory component subjected to high temperatures and a dashboard configured to monitor the refractory component, particularly to evaluate the thickness, average temperature, or damage condition of the refractory component. Background Technology

[0003] Generally speaking, a "furnace" refers to a device or reactor that includes a chamber and a heating system designed to establish temperatures above 800°C within the chamber.

[0004] Furnaces are specifically used to manufacture molten products, such as those used in the production of metallurgical or glass products, and also for incinerating waste or generating energy from fuel. For example, a reactive gas turbine is considered a furnace.

[0005] The furnace can consume gas or other fuels, or be supplied with resistance, or be heated by induction.

[0006] A metallurgical furnace can be an apparatus in which metallic precursors are reduced to obtain cast iron. A metallurgical furnace can also be a metal smelting furnace or a remelting furnace. For example, a furnace can be a blast furnace used to smelt cast iron from iron ore or to remelt copper cathodes smelted through another process (e.g., for the production of copper wire).

[0007] A glass furnace can be an apparatus in which vitrifiable mixtures, particularly those containing oxides, carbonates, sulfates and nitrates, are melted and refined.

[0008] The walls of a furnace are typically protected by a refractory lining. Depending on the application, the refractory lining is subjected to different chemical and mechanical stresses. Its composition is therefore adjusted. For example, the interior of a glass furnace typically withstands temperatures of approximately 1500°C. The refractory lining in contact with the molten glass must resist the abrasion caused by the molten glass.

[0009] The composition of the refractory lining is particularly well-suited to the target application.

[0010] For example, refractory linings that come into contact with molten glass or its vapor are typically made of alumina-zirconia-silica (AZS) type refractory products that typically contain 30% to 45% zirconium oxide, products with very high zirconium oxide content (typically greater than 85% zirconium oxide), products with high alumina content (typically greater than 90% alumina), or zircon products, or chromium oxide products.

[0011] In copper cathode furnaces, refractory linings are generally based on SiC.

[0012] In blast furnaces used for cast iron, refractory linings made of SiC, corundum, SiAlON, carbon, or mullite are typically used, depending on the area of ​​the furnace being considered.

[0013] To optimize the service life of the refractory lining, measurements can be taken inside or outside the furnace. These measurements allow for more precise planning of repair operations, especially hot repairs or refractory lining replacements.

[0014] For example, temperature can be read using infrared thermal imaging technology, but this can only be done where the infrared camera is visually visible, which in particular excludes certain parts of the furnace lining. Furthermore, this solution typically does not allow for continuous monitoring.

[0015] Measuring devices that allow for continuous monitoring in a non-invasive manner (i.e., without entering the furnace) are known. Notably, WO2020025492A1 describes the use of an optical fiber network sandwiched between the cold side and the thermal insulation layer of a block sandwiched in the sidewall of a glass furnace, or passing through said insulation layer, for measuring the wear of the refractory lining. Furthermore, EP1527306A1 describes the use of optical fibers disposed within a fiber pad between a dense refractory lining and an inductor insulator to measure temperature in a metallurgical induction furnace.

[0016] However, existing technologies that allow for continuous monitoring have problems in the following aspects:

[0017] - In terms of reliability, and especially in terms of high-temperature resistance, particularly when the sensor includes polymer components,

[0018] - Regarding the interruption of furnace operation, especially the interruption of heat exchange through the cold surfaces of the refractory lining,

[0019] -Regarding the thermomechanical stress generated by the connection between the sensor and the refractory lining, and

[0020] - Regarding installation and maintenance, especially in the event of sensor failure.

[0021] Therefore, there is always a need for a technical solution that is easy to implement (install and maintain) and can continuously and reliably monitor the furnace refractory lining without significantly altering the furnace behavior, and in particular without changing the thermomechanical stresses applied to the refractory lining or disrupting heat transfer through the refractory lining.

[0022] The purpose of this invention is to at least partially satisfy this need. Summary of the Invention

[0023] This invention relates to an instrument panel for monitoring refractory components of a furnace, and particularly for refractory components having hot surfaces that withstand temperatures above 800°C or even above 1000°C, above 1200°C, above 1400°C, or above 1500°C, the instrument panel comprising:

[0024] - A support plate, preferably with a plurality of orifices passing through it, the support plate being at least partially made of a material consisting of fibers interconnected by a ceramic matrix, referred to as a "ceramic-matrix composite material", or consisting of a precursor of the ceramic-matrix composite material, preferably consisting of a ceramic-matrix composite material or a precursor of the ceramic-matrix composite material;

[0025] - The sensor is supported by the support plate.

[0026] As seen in more detail elsewhere in the specification, the inventors have discovered that plates made of ceramic-matrix composite materials constitute sensor supports particularly well-suited for the target application. The ceramic-matrix composite material exhibits excellent high-temperature resistance and effectively protects the sensor, especially from mechanical shock. It is easy to handle and install.

[0027] Furthermore, the inventors discovered that the presence of the orifice restricts interaction with the refractory components. In particular, the presence of the instrument panel on the refractory component provides virtually no additional mechanical stress or thermal insulation. Therefore, the furnace does not need to be modified for the installation of the instrument panel, especially when the surface of the refractory component to which the instrument panel is fixed is cooled (e.g., by blowing air).

[0028] Furthermore, the inventors discovered that the presence of the orifice significantly reduces the transmission of mechanical stress to the sensor, thus improving reliability.

[0029] Finally, the shape of the dashboard can be adapted to the surface of the refractory component, thereby improving the accuracy of the measurements taken.

[0030] It is worth noting that the dashboard may also include one or more of the following optional and preferred features:

[0031] —At least one orifice, preferably each orifice has an equivalent diameter greater than 3 mm and / or less than 50 mm;

[0032] —Perforation percentage, equal to the following ratio:

[0033] - The cumulative surface area of ​​the orifice, or "perforation surface area", is related to

[0034] - The surface area of ​​the support plate, including the perforated surface area, is greater than 5%, preferably greater than 50%, and / or less than 95%;

[0035] —A sensor is a sensor used to measure optical signals, electrical signals or acoustic signals, preferably selected from thermocouples, piezoelectric sensors, stress gauges, optical fibers, ultrasonic propagation optical fibers and acoustic sensors;

[0036] —The thickness of the support plate is 1 to 20 mm;

[0037] —The same or different, preferably the same, orifices are evenly distributed in at least one “perforated” area of ​​the support plate;

[0038] —The support plate has several perforated areas and at least one reinforcing area or “non-perforated area” that separates two of the perforated areas, and the width of the reinforcing area is greater than the maximum size of the orifice;

[0039] —A ceramic-matrix composite material or a ceramic-matrix composite material precursor comprises multiple stacked fabrics and one or more identical or different sensors, such as temperature sensors and deformation sensors, preferably sandwiched between two of the fabrics;

[0040] —The sensor is

[0041] - Embedded within a ceramic-matrix composite material or the precursor of said ceramic-matrix composite material, preferably sandwiched between two fabrics, or

[0042] -Integrated into the fiber arrangement of a ceramic-matrix composite material or a precursor of the ceramic-matrix composite material, such as weft yarns, warp yarns, or knitted fabrics, or

[0043] - Recessed in a recess formed or inserted in a ceramic-matrix composite material or a precursor of said ceramic-matrix composite material, preferably in a recess formed on the large surface of a support plate, for example in a bag, sheath, tube open at both ends, sash or shell open at one end, or

[0044] - The large surface of the support plate is preferably attached by fire-resistant adhesive, tape, clips or wire;

[0045] —The fiber accounts for more than 25% and less than 70% of the volume of the ceramic-matrix composite material;

[0046] —-Ceramic-matrix composites contain, by weight percentage, more than 80%, more than 90%, more than 95%, or even essentially 100% of one or more of the following oxides or non-oxides: Al2O3, ZrO2, HfO2, Cr2O3, MgO, CaO, SiO2, SiC, Si3N4, SiAlON, AlN, Si2ON2, BN, B4C, silicon carbonitride, MoSi2, and carbon C;

[0047] —The ceramic-matrix composite material exhibits a compressive strength greater than 10 MPa and / or a thermal conductivity greater than 2.0 W / m² at temperatures ranging from 20°C to 500°C.-1 .K -1 .

[0048] The present invention also relates to a measuring device comprising an instrument panel according to the invention and a measuring apparatus that communicates with a sensor to receive and interpret signals emitted by the sensor.

[0049] Preferably, the measuring device uses the signals it receives from the sensor to provide information relating to:

[0050] - The thickness of refractory components, especially when the dashboard is attached to the cold side of the block and when the hot side of the refractory component is in contact with molten material (e.g., glass or metal), or

[0051] -The average temperature of the refractory components, or

[0052] - The physical state of the refractory components, such as whether the refractory components have undergone phase transformation or damage, such as spalling, internal cracks, phase transformations related to penetration, or oxidation in the case of refractory components made of non-oxide materials.

[0053] Those skilled in the art know to select a sensor that is appropriate for the desired information.

[0054] The present invention also relates to a furnace including a measuring device according to the present invention.

[0055] The furnace may also include one or more of the following optional and preferred features:

[0056] - The furnace is selected from glass melting furnaces, metallurgical furnaces, incinerators, gasification furnaces, combustion chambers intended for power generation, and gas reforming units intended for the chemical industry.

[0057] - The furnace contains molten material, especially molten glass or metal, or a gaseous environment with a temperature above 800°C;

[0058] - The furnace includes refractory components, and the instrument panel is configured to contact the surface of the refractory components, preferably to mate with said surface;

[0059] - The refractory component is the side wall or bottom plate of the furnace trough, or a block of the side wall or bottom plate;

[0060] - The refractory component has a side with an expected temperature above 800°C, referred to as the "hot side", and a side facing away from the hot side, referred to as the "cold side", and the instrument panel is configured to contact the cold side, while the hot side preferably contacts the interior of the furnace;

[0061] - The refractory component is a first refractory block adjacent to the second refractory block, and the dashboard is disposed between the first refractory block and the second refractory block, preferably squeezed or "compressed" between the first refractory block and the second refractory block;

[0062] - The first refractory block is denser than the second refractory block, and the second refractory block can be an insulating block in particular;

[0063] - The dashboard extends against the vertical or horizontal surface of the fire-resistant component, especially if the fire-resistant component is a recessed block or a grooved block;

[0064] - The surface area of ​​the instrument panel (including the surface area of ​​the orifices) accounts for more than 20% of the surface area of ​​the fire-resistant component it is attached to;

[0065] - The coefficient of thermal expansion of the ceramic-matrix composite material of the dashboard is equal to ±20% of the coefficient of thermal expansion of the refractory component material;

[0066] - The instrument panel is attached to the refractory component so that thermomechanical stress is not applied to the refractory component due to dimensional changes in the refractory component caused by the nominal operation of the furnace. Attached Figure Description

[0067] Other features and advantages of the invention will become clearer from the following detailed description and by examining the accompanying drawings, wherein:

[0068] -[ Figure 1 ] Figure 1 A half-section of an example of a glass furnace is schematically shown;

[0069] -[ Figure 2 ] Figure 2 A half-section of an example of a metallurgical induction furnace is schematically shown;

[0070] -[ Figure 3 ] Figure 3 A schematic front view of a first example of a dashboard according to the invention is shown;

[0071] -[ Figure 4 ] Figure 4 A front view of a second example of a dashboard according to the invention is shown schematically;

[0072] -[ Figure 5 ] Figure 5 A front view of a third embodiment of a dashboard according to the invention is shown schematically;

[0073] -[ Figure 6 ] Figure 6 A front view of a fourth embodiment of the dashboard according to the invention in its use position is shown schematically.

[0074] -[ Figure 7 ] Figure 7 A front view of a fifth embodiment of a dashboard according to the invention is shown schematically;

[0075] -[ Figure 8] Figure 8 A cross-section of a sixth embodiment of a dashboard according to the invention is schematically shown;

[0076] -[ Figure 9 ] Figure 9 A cross-section of another example of a dashboard according to the invention is shown schematically;

[0077] -[ Figure 10 ] Figure 10 A cross-section of yet another example of a dashboard according to the invention is schematically shown;

[0078] -[ Figure 11 ] Figure 11 The bending deformation of the dashboard in a preferred embodiment of the invention is shown;

[0079] -[ Figure 12 ] Figure 12 The instrument panel according to the invention is shown positioned between the refractory blocks of the furnace;

[0080] -[ Figure 13 ] Figure 13 A vertical cross-section of one embodiment is shown, in which two stacked blocks are inserted between the two blocks.

[0081] The same reference numerals are used to denote the same or similar components. Detailed Implementation

[0082] definition

[0083] "Refractory component" is understood to refer to an element of a furnace made of refractory material. A refractory component can be a block, or an assembly of blocks, such as the sidewalls or bottom plates of a trough, especially formed by casting. Refractory components are typically made of molten or sintered material. Typically, an insulating layer covers the cold surfaces of the refractory component to limit heat exchange. For example, an insulating layer may be absent in a portion of the refractory lining of an incinerator or blast furnace.

[0084] Typically, when a refractory component has a hot surface, its "thickness" is a dimension measured in a direction perpendicular to its hot surface. For example, for a tank-side block in contact with molten glass or metal, the thickness is measured in a substantially horizontal direction toward the molten glass or metal bath. For a base plate, the thickness is measured in a vertical direction.

[0085] A "hot face" is the surface of a refractory component exposed to furnace space above 800°C, such as that containing or intended to contain molten glass or metal. A hot face may be in contact with or intended to be in contact with the molten glass or metal and / or with a gaseous environment extending above the molten glass or metal. Therefore, a hot face is the surface of a refractory component that is subjected to or intended to be subjected to the highest temperature. All hot faces of the block of the sidewall of the glass or metal melting tank can also be described together as "hot faces" by extension. The upper surface of the base plate can also be described as a "hot face".

[0086] For clarity, the adjective "hot" will be used. Before the furnace was put into use, the "hot" side was the side intended to withstand the highest temperatures after it was put into use.

[0087] A "cold face" is the surface area of ​​a refractory component that is not exposed to the space of a furnace heated to above 800°C; that is, it is isolated from this space by the material of the refractory component. The cold face, opposite to the hot face, is the face furthest from said space. Typically, the cold face, opposite to the hot face, is the face that is subjected to or intended to withstand the lowest temperatures during use. The cold face may be parallel to the hot face.

[0088] "Usage location" is a configuration in which the instrument panel is placed on the surface (e.g., the cold surface) of a refractory component in order to obtain measurements related to the refractory component.

[0089] The term "plate" generally refers to an assembly having two substantially parallel large faces and a thickness relatively small relative to the surface area of ​​the large faces, with the thickness direction perpendicular to the large faces. The ratio of "maximum thickness of large faces / surface area" is preferably less than 1 / 500m². -1 Preferably less than 1 / 1000m -1 Preferably less than 1 / 5000m -1 And preferably less than 1 / 10,000m -1 .

[0090] The "surface area" of a board is the area within its perimeter. Therefore, the surface area of ​​a board includes the surface area defined by the material of the board and the surface area through the openings in the board.

[0091] The thickness of the dashboard is its dimension measured perpendicular to the large surface of the dashboard intended for positioning or abutment against refractory components.

[0092] The orifice through the plate is an orifice having a first opening and a second opening leading to a first large face and a second large face of the plate. The orifice is preferably straight and preferably extends perpendicular to the large face of the plate. The "surface area" of the orifice is the surface area of ​​its opening on one side of the refractory component against which the plate is intended to be placed. The length of the orifice is the maximum dimension of the opening. Its width is the maximum dimension of the opening perpendicular to its length.

[0093] "Perforated surface area" should be understood as the cumulative surface area of ​​all surfaces at the opening.

[0094] The percentage of perforation in a perforated area (or dashboard) is the ratio of the perforated surface area of ​​the perforated area (or the dashboard) to the surface area of ​​the perforated area (or the dashboard), which includes the perforated surface area.

[0095] The "equivalent diameter" of an orifice is the diameter of a disk with the same surface area as the orifice.

[0096] "Melted product," often referred to as "electromelizable," should be understood to mean a product obtained by the complete solidification of a liquid composition obtained by melting a mixture of suitable raw materials in an electric arc furnace or by any other suitable technique.

[0097] "Sintered product" should be understood to mean a product obtained by mixing appropriate raw materials, shaping the mixture in a green state, and firing the green form at a temperature and time sufficient to sinter the green form, which can be fired in situ during use.

[0098] "Ceramic-matrix composite" or "CMC" is generally understood to refer to products composed of fibers interconnected by a ceramic matrix. The choice of fibers depends on the environment in which the ceramic-matrix composite is used, especially on conditions related to temperature, corrosion, thermal cycling, expansion, and the nature of the refractory component to be provided.

[0099] The arrangement of the fibers constituting the fiber support for the matrix is ​​selected based on the desired shape of the ceramic-matrix composite and the ease with which the sensor can be attached. For example, a stack of woven fabric or insulating pads is well-suited for simple boards, filament winding is well-suited for boards with rotationally symmetrical geometry, and filament placement is well-suited for large, complex shapes.

[0100] "Ceramic-matrix composite precursor" is a material that can be transformed into the ceramic-matrix composite material under heating, preferably to a temperature greater than 600°C, preferably to a temperature greater than 700°C, and preferably under sintering.

[0101] The fibers are usually in the form of fabric. CMC can then be described as "ceramic-matrix fabric".

[0102] The fabric can be:

[0103] - The ordered two-dimensional structure of fibers or yarns, especially knitted, woven, or machine-woven fabrics, or

[0104] - A random two-dimensional structure of fibers or yarns, which is not preferred.

[0105] Textiles are particularly different from fiber mats, where the organization of fibers or yarns is random in three spatial dimensions.

[0106] A "fiber" is a filament whose length is greater than five times its equivalent diameter. The "diameter" of a fiber is the diameter of a disk with the same surface area as its cross-section.

[0107] "Yarn" is an aggregate of fibers that contains more than 10, preferably less than 500,000 fibers in its cross-section and has a length greater than 5 times its diameter.

[0108] "Ceramic" is understood to mean a product that is neither metallic nor organic. Within the scope of this invention, carbon is considered a ceramic product.

[0109] "Skin" is generally understood to refer to the outer area of ​​the molten block made of molten material, which is less than 5 millimeters (mm) from the mold wall when it solidifies.

[0110] "Machining" should be understood as the correction operation used to machine the surface of refractory parts to obtain a precise surface geometry.

[0111] For clarity, the chemical formulas of the oxides are used to indicate the amount of these oxides in the composition. For example, “ZrO2”, “SiO2”, or “Al2O3” indicates the amount of these oxides, and “zirconia”, “silicon dioxide”, and “alumina” are used to indicate the phases of these oxides composed of ZrO2, SiO2, and Al2O3, respectively.

[0112] Unless otherwise stated, all oxide contents are based on a percentage by mass of oxides. The mass content of oxides of a metallic element refers to the total content of that element expressed in its most stable oxide form according to standard industrial practice.

[0113] The horizontal plane of an object is a plane that is perpendicular to the length direction of the object.

[0114] "Horizontal" and "vertical" are understood to mean orientations that form angles of less than 5°, or even less than 2°, or even less than 1° with perfectly horizontal and vertical planes, respectively.

[0115] The terms “include”, “contain”, or “have” should be interpreted in a non-restrictive manner.

[0116] Detailed description

[0117] Furnace – Refractory Components

[0118] The furnace according to the invention can be any conventional furnace, particularly selected from glass furnaces, metallurgical furnaces, waste incineration plant furnaces, gasifiers, power generation furnaces (especially gas turbines), and gas reforming units for the chemical industry.

[0119] The present invention preferably relates to glass melting furnaces. However, the invention is not limited to this preferred application.

[0120] Figure 1 A schematic half-cross-section of the glass furnace 10 is shown. The tank 12, the metal structure 14, and the upper structure 16 can be distinguished.

[0121] The tank 12, intended to contain molten glass, has vertical sidewalls 22 and a bottom plate 24. The sidewalls 22 are typically formed by sidewall blocks that extend along the entire height of the tank to the upper edge 25.

[0122] Figure 1 The thermal insulation layer, not shown, is typically disposed against the cold side of the sidewall. In particular, the insulation layer may surround the sidewall of the glass melting tank of the furnace.

[0123] The superstructure 16 typically includes an intermediate layer 18 (which rests on a metal structure via the intermediate layer 18), sidewalls 26 resting on the intermediate layer 18, and a top 28. Burners, not shown, are disposed in the sidewalls 26 and operate alternately.

[0124] A metal structure 14, typically made of cast iron, surrounds the sidewall 22 of the groove on the outside. It supports the weight of the superstructure 16.

[0125] The intermediate layer 18 comprises and is preferably made of the following: filling brick 20.

[0126] Therefore, the furnace chamber is defined by various components subjected to different chemical and mechanical stresses. This invention is particularly useful for monitoring the refractory components in contact with molten glass, and especially for monitoring the condition of the sidewalls and bottom plate of the furnace.

[0127] Fire-resistant components can be, in particular, the top, sidewalls of the superstructure, intermediate layers, sidewalls of the trough, bottom plates, top blocks, sidewall blocks of the superstructure, intermediate layer blocks, sidewall blocks of the trough, or bottom plates.

[0128] The present invention also relates to a metallurgical furnace. In particular, Figure 2 A cross-section of a crucible for an induction furnace is schematically shown, for example, for remelting and / or processing metals, such as dephosphorizing. The crucible includes sidewalls 110 extending substantially vertically from a base 112.

[0129] The sidewall 110 of the crucible typically includes, from the outside to the inside of the crucible:

[0130] - Support layer 114, on which inductor 116 is attached;

[0131] -At least one thermal insulation layer 118;

[0132] - At least one electrically insulating layer 120;

[0133] - Refractory lining 122, which defines the inner surface 128 of the crucible.

[0134] The base 112 typically includes, from the outside to the inside of the crucible:

[0135] -The base plate is basically horizontal, 130;

[0136] - Refractory lining 122', which defines the inner surface 128 of the crucible.

[0137] During operation, temperatures can typically exceed 800°C, or even 1000°C or 1200°C, or even 1300°C or 1400°C, depending on the metal being considered. Temperatures are generally below 1700°C.

[0138] The refractory components may be, in particular, a support layer 114, a thermal insulation layer 118, an electrical insulation layer 120, a refractory lining 122 in direct contact with metal, a base plate 130, a refractory lining 122', or one or more blocks of the thermal insulation layer 118, the electrical insulation layer 120, the refractory coating 122, the base plate 130, and the refractory coating 122'.

[0139] Refractory components can be the parts of the furnace that do not come into contact with the interior of the furnace chamber.

[0140] Refractory components can be, in particular, recessed beams or blocks, upright bricks, refractory bricks or sidewall blocks, corner blocks, filling bricks, paving bricks or pavements, arch bricks or beams, blocks or bricks around tuyeres, or bricks for steel outlets or nozzles, electrode blocks, injector blocks, refractory flow channel outlet lips for glass furnaces, blocks for injectors, glass furnace recesses, components for heat exchangers of furnaces, in particular exchanger tubes, refractory bricks or plates, in particular boiler lining bricks or tubes, protective shells for heater tubes of incinerators, bricks for incinerators, ceramic components for solar absorbers, protective components or bricks for turbine combustion chambers, in particular gas turbine chambers, blocks or surrounding areas of tuyeres or burners.

[0141] Preferably, the refractory components are rigid, such as blocks or block assemblies, and are preferably consolidated, and in particular sintered or fused.

[0142] This invention is particularly suitable for refractory components having a hot side that contacts the furnace interior, preferably the molten material, and a cold side opposite the hot side. The instrument panel specifically enables the detection of abnormal or excessive penetration of molten material into the refractory component, penetration that is not always detectable using conventional furnace monitoring tools.

[0143] Refractory components can be made from molten products, i.e., products obtained by melting refractory mixtures to temperatures above 1000°C, preferably above 1500°C, or even above 1800°C.

[0144] Refractory components can be made from sintered products, i.e. products obtained from refractory mixtures that are preferably formed and sintered at temperatures above 600°C, preferably above 1000°C.

[0145] In the target application, the chemical composition of the refractory component can be a known composition used for conventional linings.

[0146] The refractory components are preferably formed from refractory blocks or assemblies of multiple refractory blocks.

[0147] Preferably, the one or more refractory blocks are prefabricated, i.e., obtained from refractory mixtures (e.g., refractory concrete or rammed mixes), shaped, and then baked at a temperature preferably below 600°C.

[0148] The refractory component preferably comprises more than 95%, more than 97%, more than 99%, more than 99.5%, and more than 99.9% of its mass, and is preferably composed of refractory oxides and / or non-oxides.

[0149] In one embodiment, the refractory component has a chemical composition based on the mass percentage of oxides, such that Al2O3+ZrO2+SiO2+Cr2O3>80.0%.

[0150] In one embodiment, the preferred molten refractory component has the following chemical composition: containing, by mass percentage of oxides, greater than 0.5%, or even greater than 1.5%, or even greater than 3.0%, or even greater than 4.0%, or even greater than 5.0%, or even greater than 6.0%, and / or less than 10.0%, or even less than 9.0%, or even less than 8.0% of zirconia stabilizer, particularly CaO and / or Y2O3 and / or MgO and / or CeO2, preferably Y2O3 and / or CaO, preferably Y2O3.

[0151] In one embodiment, the refractory component is a molten product and may also include one or more of the following optional features:

[0152] - At least some, preferably all, surfaces of refractory components intended to be exposed to the furnace environment have a skin microstructure. In particular, at least some, preferably all, of the groove surfaces and / or transition surfaces preferably have a skin microstructure;

[0153] - The crystal density of a surface with epidermal microstructure is less than 30 times, or even less than 25 times, or even less than 20 times the crystal density measured at a depth of 4 cm below the surface.

[0154] Obtaining a skin microstructure on the surface of a molten component (i.e., a component made from a molten product) does not pose any particular difficulty to those skilled in the art. In particular, those skilled in the art will know that the microstructure on the surface can be made finer by increasing the solidification rate of the molten material.

[0155] When a bath of molten material is poured into a mold, the mold's properties and temperature can be specifically adapted to ensure sufficiently rapid cooling to obtain a skin microstructure. For example, if the mold is initially at ambient temperature, a skin microstructure forms on the surface in contact with or near the mold wall. In contrast to established practices, if this skin is not removed during machining operations, the resulting microstructure is a skin microstructure on the surface of the unmachined refractory component.

[0156] However, limited machining (planing) allows for the preservation of the epidermal microstructure.

[0157] Of course, the composition, size, shape and microstructure mentioned above are not limited.

[0158] The fact that the dashboard closely conforms to the shape of the fire-resistant components contributes advantageously to the optimal performance of the sensors.

[0159] Dashboard

[0160] A dashboard is an "instrument" that takes the form of fine components or layers and is used to perform measurements.

[0161] Figures 3 to 8 An example of Dashboard 300 is shown.

[0162] The dashboard can be set against any surface, but it is particularly useful for surfaces that are at least partially covered at temperatures above 150°C, above 300°C, above 400°C, and / or below 800°C.

[0163] like Figure 6 As explained, in the usage position, the instrument panel 300 extends against the surface of the fire-resistant component P (the cold surface F in this embodiment).

[0164] The portion of the refractory component that contacts the instrument panel 300 can be flat, such as the recessed top plate defined for a glass furnace or the brick of a gas turbine. It can be flat, straight, or curved, for example, the surface of the filling brick in the specific case of a glass furnace. Preferably, it is flat.

[0165] Figure 6 One embodiment is shown in which the cold side F of the refractory component, opposite to the hot side C, adopts an overall shape of a corner profile formed by two facets that may extend perpendicularly to each other.

[0166] Preferably, the instrument panel 300 has a constant average thickness e between the large surfaces G1 and G2 (see [reference]). Figure 8 The thickness is less than 40 mm, preferably less than 32 mm, preferably less than 28 mm, preferably less than 22 mm, preferably less than 20 mm, preferably less than 10 mm, or even less than 18 mm or 15 mm, and / or preferably greater than 1 mm, preferably greater than 2 mm, or even greater than 3 mm or greater than 5 mm. The preferred thickness is 1 to 20 mm, preferably 2 to 10 mm, especially to allow for easy insertion between the refractory components and the rear thermal insulation of the furnace or the outer sheath, while still allowing the instrument panel 300 sufficient mechanical strength.

[0167] The surface area of ​​the instrument panel 300 is preferably greater than 100 cm². 2 Preferably larger than 200cm 2 Preferably larger than 300cm 2 Preferably greater than 400cm 2 and / or less than 20,000 cm 2 Preferably less than 15,000 cm 2 Or even less than 10,000 cm 2 .

[0168] Preferably, the instrument panel 300 extends over a surface area of ​​more than 20%, or even more than 30%, more than 40%, more than 50%, more than 60%, more than 70%, more than 80%, more than 90%, or even 100% of the surface of the refractory component that houses it.

[0169] Preferably, the dashboard 300 is prefabricated, i.e. manufactured before being attached to the refractory components.

[0170] The instrument component 300 preferably has sufficient rigidity to be self-supporting, that is, to maintain its shape when handled at ambient temperature (20°C). In the usage position, the sensor is thus effectively held in place.

[0171] Preferably, the instrument panel 300 has a shape complementary to the shape of the surface on which the instrument panel is intended to be abutted or the surface on which the instrument panel 300 is abutted.

[0172] For example, it can be disposed or even attached to a receiving portion formed on the surface, such as in its embodiment disposed between two adjacent blocks, as... Figure 12 and 13 As shown.

[0173] In particular, the dashboard 300 can take the form of a flat plate with multiple flat surfaces, or it can have a cylindrical shape.

[0174] The rigidity of the instrument panel 300 is preferably such that it can be bent by hand, such as Figure 11 As shown. Advantageously, it can therefore better fit the shape of the surface that houses the refractory component.

[0175] In one embodiment, the instrument panel 300 takes the form of a roller before being fixed to the refractory component.

[0176] According to the present invention, the instrument panel 300 has a perforated area 302, that is, an area through which a plurality of orifices 304 pass.

[0177] Perforation significantly limits the impact of the instrument panel on the operation of the refractory components, and particularly on heat transfer. Perforation also reduces the thermomechanical stresses that the instrument panel exerts on the refractory components.

[0178] The percentage of perforations in the perforated area, preferably any perforated area, preferably the instrument panel, is preferably greater than 5%, preferably greater than 10%, preferably greater than 15% or even greater than 20%, greater than 30%, greater than 40%, greater than 50% and / or less than 95%, preferably less than 90%.

[0179] Figure 5 An example of a dashboard with a very high perforation percentage is provided, which uses a grid-like overall form.

[0180] The shape and distribution of the orifices 304 can be configured in various ways depending on the size of the refractory component.

[0181] In the perforated area, preferably in each perforated area 302, the orifices 304 are evenly distributed.

[0182] In the perforated area 302, preferably in each perforated area, the openings may have the same or different, preferably the same shape and / or size.

[0183] The shape of the orifice 304 is preferably elliptical or circular, such as... Figure 6 As shown, or in the form of a polygon, preferably a rectangle, square, or rhombus, such as... Figure 3 and Figure 4 As shown.

[0184] Preferably, the equivalent diameter and / or length and / or width of at least one orifice 304, preferably each orifice in the perforation area 302, preferably each orifice in each perforation area is greater than 2 mm, greater than 3 mm and / or less than 300 mm, preferably less than 200 mm, preferably less than 150 mm, preferably less than 100 mm, preferably less than 50 mm.

[0185] Preferably, to minimize the impact on heat transfer, the surface area of ​​each orifice 304 is 4 mm. 2 Up to 1000cm 2 .

[0186] The cross-section of orifice 304 in a section perpendicular to the thickness direction of the instrument panel can be constant or variable in the section under discussion. Variation of the cross-section advantageously allows for local definition of mechanical resistance characteristics, such as the manner in which the instrument panel deforms.

[0187] In the perforated area 302, the orifices 304 are preferably evenly distributed in each perforated area. Preferably, each orifice is separated from all adjacent orifices by a distance greater than 0.5 mm, preferably greater than 1 mm, preferably greater than 2 mm and / or less than 50 mm, preferably less than 40 mm, preferably less than 30 mm, preferably less than 20 mm, preferably less than 15 mm, preferably less than 10 mm, preferably less than 5 mm.

[0188] Perforated region 302, preferably each perforated region, preferably in an integral form having a grid, sieve or lattice.

[0189] In one embodiment, the instrument panel 300 has a plurality of perforated areas 302, preferably evenly distributed on the instrument panel, said perforated areas being separated by areas without openings (referred to as "reinforced areas" 306), such as Figure 4 As shown. In one embodiment, all reinforcement zones form a regular pattern, such as a frame or grid pattern.

[0190] The reinforced area contributes to the mechanical strength of the dashboard.

[0191] The width l of the reinforcing zone, i.e., the minimum distance between the two perforated zones it separates, is preferably any width of the reinforcing zone, and is preferably...

[0192] - Greater than 5mm, preferably greater than 10mm, preferably greater than 15mm and / or preferably less than 200mm, preferably less than 150mm, preferably less than 100mm, or even less than 80mm, and / or

[0193] - is greater than, preferably greater than 2 times, preferably greater than 3 times and / or preferably less than 20 times the maximum size of the opening of the perforated area it divides.

[0194] Preferably, the thickness of the reinforcing region 306 is the same as the thickness of the perforated region.

[0195] The dashboard 300 can maintain contact with the fire-resistant components by any known means of the prior art.

[0196] The surface of the instrument panel housing the fire-resistant component can be slotted or machined to form a recess or housing portion for attaching the instrument panel, for example, by clamping or pinching.

[0197] Typically, the instrument panel is preferably fixed to the refractory component so that no thermomechanical stress is applied to the refractory component during normal or "nominal" operation of the furnace due to dimensional changes in the refractory component.

[0198] Preferably, the dashboard is not attached to its entire surface area, but rather attached via attachment points and / or attachment lines.

[0199] In one embodiment, the instrument panel 300 is inserted between two facing surfaces of two adjacent refractory blocks, particularly the vertical or horizontal surfaces. Preferably, it is compressed between these surfaces so that it does not need to be attached to said surfaces.

[0200] In one embodiment, the dashboard 300 is fixed to the surface by means of a shape complementary to that of the surface in which it is housed.

[0201] The instrument panel 300 can also be bonded to a fire-resistant component. Preferably, the adhesive used to attach the instrument panel is selected from a mixture of ceramic powder and adhesive, and is preferably applied in liquid form.

[0202] Preferably, the powder is alumina and / or silica and / or mullite powder. Preferably, the binder is selected from colloidal silica, sodium silicate, organic resins, organic binders, and mixtures thereof. The binder used may also be a commercial binder, such as Fixwool Adhesive FX from Unifrax.

[0203] The instrument panel 300 includes a support plate 310 and one or more sensors 312 supported by the support plate 310, preferably integrated into the support plate 310, for example... Figures 8 to 10 As shown.

[0204] In one embodiment, the support plate 310 or even the instrument panel 300 is manufactured in situ, particularly sintered, that is, on the refractory component. The instrument panel 300 can be considered as a "layer" covering the refractory component's accommodating surface, that is, the instrument panel 300 extends against that surface.

[0205] CMC

[0206] The support layer 310 comprises, preferably, a ceramic-matrix composite material, or “CMC”, or a CMC precursor.

[0207] Those skilled in the art will know how to adjust the CMC precursor according to the desired CMC. Therefore, only a detailed description of CMC is given below.

[0208] The support plate 310 defines the overall shape of the instrument panel and serves as a support for one or more sensors.

[0209] CMC has been shown to be particularly resistant to thermal degradation. CMC also exhibits good resistance to corrosive substances containing soda vapor.

[0210] Preferably, CMC is sintered in air at atmospheric pressure.

[0211] Preferably, the open porosity of the CMC, measured by suction according to Archimedes' principle of buoyancy, is greater than 25%, more preferably greater than 30% and less than 45%, more preferably less than 35%.

[0212] The apparent density of CMC is preferably greater than 1.4 g / cm³. 3 or even greater than 1.50 g / cm³ 3 and / or less than 2 g / cm 3 Preferably less than 1.9 g / cm³ 3 Preferred concentration is less than 1.80 g / cm³. 3 .

[0213] In particular, when the dashboard is attached to the cold surface of a refractory component, for example by adhesive bonding or mechanical attachment (e.g., by inserting a groove), it is preferred if the coefficient of thermal expansion of the CMC (also known as the coefficient of thermal expansion) differs from that of the refractory component material by no more than 20%. The coefficient of thermal expansion of the CMC can be set using techniques well known to those skilled in the art, particularly by adjusting the composition of the CMC. For example, silica has a coefficient of thermal expansion of 0.510 at temperatures ranging from 20°C to 1000°C. - 6 mK -1 The alumina content is 8.0.10. -6 mK -1 SiC is 4.5.10. -6 mK -1 And the carbon content is less than 1.0.10. -6 mK -1 .

[0214] In one embodiment, the absolute value of the difference between the thermal conductivity of the CMC and the thermal conductivity of the refractory component is less than 10% of the thermal conductivity of the CMC at 20°C to 500°C, preferably less than 2.0 W / m². -1 .K -1 .

[0215] In one embodiment, the thermal conductivity of the CMC from 20°C to 500°C is greater than 2.0 W / m². -1 .K -1 Preferred strength is greater than 5.0 Wm -1 .K -1 or even greater than 10W.m -1 .K -1 or even greater than 50W.m -1 .K -1 .

[0216] To obtain a given coefficient of thermal expansion and / or a given thermal conductivity, the simple text allows for the determination of the amount of fibers of silica, alumina, SiC, and carbon, and / or the amount of the matrix of silica, alumina, SiC, and carbon. For example, the thermal conductivity of CMC can be adjusted by combining fibers (e.g., thermally conductive fibers of graphite or SiC) with a relatively insulating matrix (e.g., an alumina matrix), or by combining a thermally conductive matrix (e.g., a SiC matrix) with relatively insulating fibers (e.g., fibers of alumina or silica).

[0217] Preferably, the three-point flexural strength of the CMC, measured according to standard ASTM C1341-13, is greater than 3 MPa, preferably greater than 6 MPa, and most preferably greater than 10 MPa. Advantageously, this further improves mechanical strength, especially its impact resistance.

[0218] Preferably, the CMC, especially the ceramic-matrix fabric form, has very high resistance to compression damage, for example, greater than 5 MPa, preferably greater than 10 MPa, as measured below, thereby improving the stability of the sensor. This resistance to compression damage is particularly greater than that of layers composed of insulating pads.

[0219] To measure the compressive strength of a layer of thickness e, dimensions equal to 50x50x10mm are deduced from it. 3 The sample, with a dimension of 10 mm in the thickness direction e, was then subjected to a moving motion along the thickness direction at a rate of 0.1 mm / min over the entire 50 x 50 mm area of ​​the sample at ambient temperature. 2 A load is applied to the surface area. The load is increased until the sample thickness is reduced by half (i.e., 5 mm). The compressive strength is equal to the obtained load in Newtons divided by the surface area to which the load is applied (25 cm² in this example). 2 ).

[0220] Preferably, the melting or sublimation temperature of CMC is above 600°C, more preferably above 1000°C. Advantageously, this results in no need for cooling during use.

[0221] CMC is preferably made from one or more of the following oxides or non-oxides: Al2O3, ZrO2, HfO2, Cr2O3, MgO, CaO, SiO2, SiC, Si3N4, SiAlON, AlN, Si2ON2, BN, B4C, silicon carbonitride, MoSi2, and carbon C, especially in the form of amorphous carbon, graphite, or graphene. Therefore, it exhibits particularly good resistance to thermal degradation.

[0222] Preferably, more than 90% by mass, more than 95% by mass, more than 98% by mass, more than 99% by mass, and more than 99.5% by mass of CMC are composed of oxides.

[0223] Particularly and preferably, the total amount of Al2O3, SiO2, ZrO2, CaO, Na2O, MgO, K2O, TiO2, Fe2O3, HfO2, Cr2O3, P2O5, and Y2O3, or “Al2O3+SiO2+ZrO2+CaO+Na2O+MgO+K2O+TiO2+Fe2O3+HfO2+Cr2O3+P2O5+Y2O3”, based on the mass percentage of CMC oxides, is preferably greater than 80%, preferably greater than 85%, preferably greater than 90%, or even greater than 95%.

[0224] In one embodiment, the CMC has a chemical composition based on oxide mass percentages such that Al2O3+SiO2+ZrO2+CaO+Na2O+MgO+K2O+TiO2+Fe2O3+HfO2+P2O5+Y2O3 > 85%, preferably greater than 90%, or even greater than 95%. Preferably, it has a chemical composition based on oxide mass percentages such that the total content of Al2O3+SiO2+ZrO2+CaO+Na2O+MgO+K2O+TiO2+Fe2O3+HfO2, based on oxide mass percentages, is greater than 80%, preferably greater than 85%, preferably greater than 90%, or even greater than 95%. Preferably, it has a chemical composition based on oxide mass percentages such that the total content of Al2O3+SiO2+ZrO2+CaO+HfO2 is greater than 80%, preferably greater than 85%, preferably greater than 90%, or even greater than 95%.

[0225] In one embodiment, the CMC has a chemical composition based on the mass percentage of oxides, such that Al2O3+SiO2 > 80%, preferably greater than 85%, preferably greater than 90%, or even greater than 95%.

[0226] In one implementation, the CMC has the following chemical analyses, expressed as a percentage of the oxide by mass, totaling 100%:

[0227] -SiO2: 47%-67%,

[0228] -Al2O3: 32%-52%,

[0229] -Oxide substances other than Al2O3 and SiO2: <5%, preferably <4%, preferably <3%, preferably <2%.

[0230] CMC fibers

[0231] Preferably, the fiber volume accounts for more than 25%, more than 30%, more than 40%, more than 50%, more than 60%, and / or less than 70% of the CMC material volume, that is, the total amount consists of up to 100% of the ceramic matrix that bonds the fibers together, without considering its porosity.

[0232] The fiber diameter, measured along half of the fiber and on average across all fibers, is 3 to 30 micrometers, preferably 5 to 25 micrometers.

[0233] Preferably, the fibers are combined to form a yarn. Each yarn preferably contains more than 10, more preferably more than 50, more preferably more than 100 fibers, and more preferably hundreds to thousands of fibers. The fibers, preferably the yarn, are preferably continuous and have a length greater than 50 mm, or even greater than 100 mm, or even greater than 1 m, greater than 10 m, greater than 100 m, or even greater than 1000 m. In one embodiment, the fibers, preferably the yarn, are arranged in the form of a fabric, particularly a woven, non-woven, knitted, or braided fabric.

[0234] The fibers of CMC comprise, preferably, ceramic fibers. Preferably, the fibers are selected from fibers consisting of more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% by mass of alumina; fibers consisting of more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% by mass of silica; fibers consisting of more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% by mass of amorphous silica; fibers consisting of more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% by mass of mullite; and fibers consisting of more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% by mass of glass, preferably leachable glass.

[0235] Advantageously, CMC has sufficient mechanical strength to resist impact and sufficient stiffness to be easily handled and attached to refractory components without deformation.

[0236] Preferably, the fiber is made of an oxide material, which preferably contains more than 50% by mass, more preferably more than 60% by mass, or even more than 70% by mass, or even more than 80% by mass, or even more than 90% by mass of Al2O3 and / or SiO2 and / or ZrO2, in mass percentage based on the oxide.

[0237] The fibers can also be made at least in part from non-oxide materials, such as SiC, another carbide, nitride, or oxynitride.

[0238] Preferably, the fiber made of a non-oxide material is selected from SiC fibers, for example... Fiber, NL, Hi or Hi-S grade fiber.

[0239] CMC substrate

[0240] The ceramic matrix or “binder phase” of CMC may contain more than 80%, more than 90%, more than 95%, or even substantially 100% by mass percentage of one or more compounds selected from the group consisting of: SiCα or β, silicon carbonitride, carbon C (especially in amorphous form), graphite or graphene, Si3N4, AlN, silicon oxynitride including SiAlON and Si2ON2, boron nitride BN, boron carbide B4C, and molybdenum disilicide MoSi2.

[0241] Preferably, more than 90%, more preferably more than 95%, more preferably more than 99% of the matrix is ​​composed of oxides, particularly by mass. Preferably, the matrix of CMC is substantially entirely composed of oxides.

[0242] In one embodiment, more than 80%, more than 90%, more than 95%, preferably substantially 100% of the matrix mass comprises, and preferably consists of, one or more compounds selected from the group consisting of Al2O3, ZrO2, Cr2O3, MgO, CaO and SiO2.

[0243] The matrix preferably comprises Al2O3 and / or SiO2, more preferably Al2O3 and SiO2. The total content of Al2O3 and SiO2, based on the weight percentage of the matrix oxides, is preferably greater than 80%, preferably greater than 85%, preferably greater than 90%, and more preferably greater than 95%. Preferably, the Al2O3 content in the matrix, based on the mass percentage of the matrix oxides, is greater than 60%, preferably greater than 65%, and more preferably greater than 70%, and / or the SiO2 content in the matrix, based on the mass percentage of the matrix oxides, is greater than 15%, preferably greater than 20%, and / or less than 35%, and more preferably less than 30%. Preferably, the content of oxides other than Al2O3 and SiO2 in the matrix, based on the mass percentage of the matrix oxides, is less than 3%, preferably less than 2%, and more preferably less than 1%.

[0244] In one embodiment, the silica matrix is ​​amorphous.

[0245] sensor

[0246] The dashboard includes one or more sensors 312.

[0247] exist Figure 3 and 6 In figure 9, the sensors are shown as dashed lines. They are not shown in the other figures.

[0248] Sensor 312 can be any known sensor. It enables the physical measurement of optical, electrical, or acoustic signals. It is preferably selected from thermocouples, piezoelectric sensors, stress gauges, optical fibers, ultrasonic fiber optics, and acoustic sensors.

[0249] Preferably, the sensor is a temperature sensor, such as a thermocouple or an optical fiber with a Bragg grating. The sensor can also be a deformation sensor, such as that described in WO2017 / 009256.

[0250] According to a particularly advantageous embodiment, the sensor 312 is in the form of a wire or wire assembly, which is attached to or incorporated into the support plate 310, preferably into the CMC of the support plate 310.

[0251] According to the first specific implementation method, such as Figure 10 As shown, the sensor is attached to the support plate 310 via an interface layer 313. Specifically, if the temperature of the surface (especially the cold side) housing the refractory component is less than or equal to 400°C, the interface layer can be an adhesive comprising a thermosetting polymer, a thermoplastic polymer, or a crosslinkable elastomer. Preferably, when the polymer is a thermosetting polymer, its degree of crosslinking is greater than 75%, or even greater than 90%. Preferably, when the polymer is a thermoplastic polymer, its crystallinity varies from 0% to 80%. Also preferably, the adhesive comprises more than 50% by mass of one or more polymers, such as polyurethane or epoxides. If the operating temperature is greater than or equal to 400°C, the interface layer is preferably an inorganic adhesive, such as a geopolymer-based adhesive, for example, containing sodium silicate, or, for example, a platinum or copper-based adhesive, or otherwise, for example, a refractory adhesive as described in the following article: R. Luhn, E. Zimmermann und G. Jena"Anorganische Hochtemperaturklebstoffe– und Grenzen"[Inorganic high-temperature adhesives-possible applications andlimitations","Schweiβen und Schneiden 2000 "The der gleichnamigen GroβenSchweiβtechnischen Tagung in Nuremberg vom 27.bis 29.September 2000" [Welding and cutting 2000: papers from the eponymous Major Welding Technology Conference in Nuremberg 27 to 29 September 2000], pp. 249 to 252, for example, Pyro-Putty #653 or 2400 ceramic adhesives from Aremco. The thickness of the interface layer is preferably constant, preferably greater than 0.1 mm and / or less than 2 mm, preferably less than 1 mm. Generally, the behavior of the adhesive can be modified by adjusting its composition, for example by changing the amount of organic materials (thermosetting polymers, thermoplastic polymers, or crosslinked elastomers), accelerators, retarders, or plasticizers it contains. It can also be filled, particularly with fillers made of elastomers or composed of polymers or mineral fibers.

[0252] According to the second embodiment, the sensor is secured or attached to the support plate 310 by means of fire-resistant tape, clips, or wires. In particular, aluminum strips, Inconel wires, or even platinum wires can be used, depending on the highest temperature reached on the surface of the fire-resistant components of the receiving instrument panel.

[0253] According to the third embodiment, wired or unwired sensors are integrated within the support plate 310, particularly within the CMC of the support plate 310. For example... Figure 9 As shown, the dashboard 300 may include, for example, two base layers 310a and 310b, in the form of fabric, preferably woven fabric, which are stacked on top of each other and the sensor 312 is disposed between them. The two base layers may be joined together by clips or during sintering to form a CMC. They may be specifically shaped to form receiving recesses for sensors (e.g., thermocouples), for example, in the form of a pocket, a tube open at both ends, a sleeve open at one end, or a shell.

[0254] Figure 7 One embodiment is shown in which a bag 314 is created at the center of a set of rectangular openings 304. A sensor 312 is disposed within the bag 314.

[0255] One or preferably two base layers are CMC of the type described above, preferably ceramic-matrix fabric. Preferably, at least one of the two base layers, preferably each, has a thickness greater than 2 mm, more preferably greater than 3 mm, more preferably greater than 5 mm and / or less than 10 mm.

[0256] According to the fourth embodiment, the sensor is housed in a fire-resistant sleeve 316 incorporated into the support plate 310 during its manufacture, or in a channel formed during or after the manufacture of the support plate 310.

[0257] According to a fifth embodiment, the fibers of the CMC are arranged in the form of a fabric, preferably a woven fabric, and the sensor, preferably a wired sensor, is incorporated into the fabric. The ceramic matrix of the CMC is preferably formed by sintering as the furnace temperature increases. This embodiment requires a matrix composition that allows for solidification by firing at temperatures below 800°C.

[0258] According to the sixth embodiment, the fibers of the CMC are arranged in the form of a fabric, preferably a woven fabric, and preferably the sensor in the form of a wire is incorporated into the fabric before being coated with a substrate and sintered at a temperature of at least 800°C.

[0259] Specifically, the fibers of the CMC can be arranged in the form of knitted, woven or braided fabrics, and the wired sensors can be knitted, woven or braided during the manufacture of the knitted, woven or braided fabrics.

[0260] Then, the integral part or the entire structure formed by the CMC-knitted, woven, or braided fabric and the sensor is covered by the ceramic matrix. Advantageously, the matrix thus acts as a protection for the sensor. The sensor is selected to resist the steps of coating and firing the ceramic matrix. This embodiment is particularly suitable for wired or ceramic sensors.

[0261] The wired sensor can be incorporated into the support plate in a preferred plane, preferably along a preferred direction or in a specific pattern.

[0262] The dashboard may include multiple sensors, for example:

[0263] - Multiple temperature sensors, such as two different fiber optic networks;

[0264] - A temperature sensor and a deformation sensor.

[0265] The sensors can be arranged entirely on two identical fabrics, or between different fabrics.

[0266] Measuring instruments

[0267] Only Figure 3 The measuring instrument 320 shown is intended to control the sensor 312, and in particular to receive and interpret the signals emitted by the sensor.

[0268] The measuring instrument 320 can be connected to the sensor via a wire 322, for example, by connecting it to a connection terminal 324 integrated in the dashboard 300. For clarity, the "sensor" 312 is considered to include a component that picks up the signal to be measured, typically a transducer, and a wire that connects the component to the connection terminal 324.

[0269] Preferably, the wires and connecting terminals are made of a refractory metal that can withstand temperatures above 400°C, such as platinum. Platinum-based fire-resistant and conductive adhesives can be used to improve electrical contact.

[0270] In a preferred embodiment, the measuring instrument 320 is not connected to the sensor 312. The sensor may specifically define a loop for non-contact measurement by sensing.

[0271] Measuring instruments typically include a processor, computer memory, and software configured to determine characteristics related to the condition of refractory components, such as average temperature or temperature distribution, or average residual thickness or residual thickness distribution, based on signals received from sensors.

[0272] Any conventional measuring instrument can be used. It is worth noting that the processing, analysis, and recording of the electrical characteristics measured by the sensor and their changes can be achieved using amplification, filtering, multiplexing, and digitization techniques known to those skilled in the art of sensors.

[0273] Communication between sensors and measuring instruments can be achieved via wired or wireless means, such as through WiFi or...

[0274] Preferably, the measuring instrument is programmed to record signals from the sensor at predetermined intervals.

[0275] Heating-cooling

[0276] The furnace may include a cooling system, such as a water tank or air tank, configured to cool the surface of the receiving instrument panel, particularly the cold surface, and / or the instrument panel itself. Preferably, the instrument panel is positioned between the cold surface of the refractory component and the cooling system.

[0277] Preferably, the main purpose of the cooling system is to cool the cold surface of the refractory components, and the sensor is protected by the ceramic matrix.

[0278] The furnace may also include heating devices, such as heating resistors. Such heating can be used to limit thermal shock and thermal gradients within the thickness of refractory components.

[0279] manufacture

[0280] Fire-resistant components and dashboards can be manufactured using any conventional manufacturing method.

[0281] The method for manufacturing a dashboard may specifically include the following steps:

[0282] - A slurry capable of forming a ceramic matrix after consolidation is arranged around the fibers, for example by impregnating one or more woven fabrics or pads, preferably yarns, preferably ceramic yarns.

[0283] - If multiple woven fabrics or pads have been impregnated, the woven fabrics and / or pads are layered, the layering being achieved by pressing or vacuum forming.

[0284] - Consolidation, preferably by drying and / or sintering, to form the matrix.

[0285] The preparation of slurries is well known to those skilled in the art. Slurries are typically suspensions, such as water-based or organic solvent suspensions, containing...

[0286] - Ceramic particles and / or ceramic-particle precursors, that is, compounds that are converted into ceramic particles during the manufacturing process of CMC, and especially during heating.

[0287] -Optional dispersants, plasticizers, lubricants and / or temporary binders.

[0288] The composition of the slurry, the size distribution of the ceramic particles or ceramic precursors, and the mineral fillers in the slurry are suitable for the type of fiber and the forming technology. For example, the slurry can be placed around or on the fiber, especially in the form of direct lamination, by infusion, injection, infiltration, or deposition at atmospheric pressure or higher pressure, or by vacuum forming at ambient temperature or higher temperature.

[0289] Consolidation can be carried out in situ, that is, when the furnace is started after it has been applied to the refractory components (e.g., and especially to the cold surface of the refractory blocks).

[0290] Before or after the drying and / or sintering, one or more sensors may be rigidly attached to a woven fabric or pad, or to a layered arrangement of one or more woven fabrics and / or pads.

[0291] Woven fabrics or mats can be layered such that the yarns of various woven fabrics or mats are substantially all in the same or different directions, for example, 45°, depending particularly on the desired mechanical properties. Layering can also be performed on a rigid support with a surface profile of a cold side having refractory components to obtain a support plate 310 with a profile approximating the profile of said surface.

[0292] The perforated surface can be obtained using any technique known to those skilled in the art. In particular, the openings can be made by drilling or waterjet cutting, for example, on CMC obtained after sintering. The openings can also be made on the fibrous components of the CMC, especially on fabrics, preferably woven fabrics, before being coated with a matrix.

[0293] The shape of the dashboard is preferably designed to fit closely to the surface of the refractory component that houses it. This shape can be given before or after the matrix has cured, for example by machining or deformation.

[0294] In one embodiment, the refractory component and / or support plate, or even the dashboard, is placed in its place of use in a green state (i.e., before sintering). The refractory component is preferably in the form of a concrete component. The sintering of the refractory component and / or support plate, or even the dashboard, is then carried out in situ in the furnace. Preferably, the ceramic matrix of the CMC is formed by sintering as the furnace temperature increases.

[0295] In one embodiment, the dashboard is attached to the refractory block before it is assembled into the furnace. Therefore, the present invention relates to a refractory block to which a dashboard according to the invention is attached before it is assembled into the furnace.

[0296] The dashboard can be attached to the cold surface.

[0297] It can also be placed between the opposite faces of adjacent refractory blocks. Figure 12 An example is shown in which a dashboard 3001 according to the invention is disposed between the horizontal planes of two stacked refractory blocks B1 and B2, and a dashboard 3002 according to the invention is disposed between the vertical planes of two side-by-side refractory blocks B2 and B3. Dashboards 3001 and 3002 can be held in place by the compression exerted by the refractory blocks extending therebetween.

[0298] Of course, the present invention is not limited to the detailed description above, which is provided by way of illustration only. It is also self-evident that the described embodiments are merely examples and can be modified, in particular by substituting technical equivalents, without departing from the scope of the invention.

[0299] In particular, the presence of openings through the support plate is especially advantageous, but the invention is not limited to this embodiment. In particular, in addition to the openings or alternatively, the support plate can have a very small thickness, thereby advantageously increasing the deformability of the instrument panel and limiting its insulation effect. The thickness can be particularly greater than 1 mm and less than 20 mm, preferably less than 10 mm, or preferably less than 5 mm.

[0300] Furthermore, in some applications, CMC is useful for contributing to the thermal insulation of the cold surface of refractory components. Preferably, its thermal conductivity at 20°C to 500°C, more preferably 20°C to 600°C, more preferably 20°C to 700°C, more preferably 20°C to 800°C, more preferably 20°C to 900°C, and more preferably 20°C to 1000°C is preferably less than 2.0 W / m². -1 .K -1 Preferably less than 1.8Wm -1 .K -1 Preferably less than 1.5Wm -1 .K -1 Preferably less than 1.3Wm -1 .K -1 Preferably less than 1W.m -1 .K -1 Preferably less than 0.9Wm -1 .K -1 Preferably less than 0.8Wm -1 .K -1 Preferably less than 0.7Wm -1 .K -1 Preferably less than 0.6Wm -1 .K -1 Preferably less than 0.5Wm -1 .K -1 .

Claims

1. A dashboard intended for monitoring refractory components of a furnace, the dashboard comprising: - A support plate (310) through which a plurality of orifices (304) pass, and the support plate is at least partially made of a material consisting of fibers interconnected by a ceramic matrix, referred to as a "ceramic-matrix composite material", or consisting of a precursor of the ceramic-matrix composite material; -The sensor (312) carried by the support plate, The ceramic-matrix composite precursor is a material that can be transformed into the ceramic-matrix composite material under heating.

2. The dashboard as claimed in claim 1, wherein Each of the orifices (304) has an equivalent diameter greater than 3 mm and / or less than 50 mm; and The percentage of perforations is greater than 5% and less than 95%, which is equal to the ratio of the cumulative surface area of ​​the orifice (304) or the "perforated surface area" to the surface area of ​​the support plate, the surface area of ​​the support plate including the perforated surface area, and The sensor (312) is a sensor used to measure optical signals, electrical signals, or acoustic signals, and The thickness of the support plate (310) is 1 to 20 mm.

3. The dashboard as claimed in claim 2, wherein, The percentage of perforations is greater than 50%.

4. The dashboard as claimed in claim 1, wherein, The orifices (304) are evenly distributed in at least one perforated area (302) of the support plate.

5. The dashboard as claimed in claim 4, wherein, The support plate has several perforated areas (302) and at least one reinforcing area (306), the reinforcing area separating the two of the perforated areas, the width of the reinforcing area ( l It is greater than the maximum size of the orifice.

6. The dashboard as claimed in claim 1, wherein, The sensor (312) - Embedded in the ceramic-matrix composite material or the precursor of the ceramic-matrix composite material, or -Integrated into the fiber arrangement of the ceramic-matrix composite material or the precursor of the ceramic-matrix composite material, or - Retained in a recess formed in or inserted into the ceramic-matrix composite material or the precursor of the ceramic-matrix composite material, or - Attached to the large surface of the support plate.

7. The dashboard as claimed in claim 1, wherein, The ceramic-matrix composite material or the ceramic-matrix composite material precursor comprises multiple stacked fabrics, with one or more sensors (312) inserted between the two fabrics.

8. The dashboard as claimed in claim 1, wherein - The fibers constitute more than 25% and less than 70% of the volume of the ceramic-matrix composite material, and The ceramic-matrix composite material contains, by weight percentage, more than 80% of one or more of the following oxides or non-oxides: Al2O3, ZrO2, HfO2, Cr2O3, MgO, CaO, SiO2, SiC, Si3N4, SiAlON, AlN, Si2ON2, BN, B4C, silicon carbonitride, MoSi2, and carbon C.

9. The dashboard as claimed in claim 1, wherein, The ceramic-matrix composite material has a compressive strength greater than 5 MPa and / or a thermal conductivity greater than 2.0 W / m² at temperatures ranging from 20°C to 500°C. -1 .K -1 .

10. A measuring device comprising an instrument panel (300) as claimed in claim 1 and a measuring instrument (320) in communication with a sensor (312) for receiving and interpreting signals emitted by the sensor.

11. A furnace selected from glass melting furnaces, metallurgical furnaces, incinerators, gasification furnaces, combustion chambers intended for power generation, and gas reforming units intended for use in the chemical industry, said furnace comprising: - Refractory components, and -The measuring device as claimed in claim 10, wherein the instrument panel (300) of the measuring device is configured to contact one surface of the refractory component.

12. The furnace as claimed in claim 11, wherein, The refractory component has a surface intended to be at a temperature greater than 800°C, referred to as the "hot surface," and a surface facing away from the hot surface, referred to as the "cold surface," and the instrument panel is configured to contact the cold surface.

13. The furnace as claimed in claim 11, wherein, The coefficient of thermal expansion of the ceramic-matrix composite material is equal to ±20% of the coefficient of thermal expansion of the refractory component material.

14. The furnace as claimed in claim 11, wherein, The instrument panel (300) is attached to the refractory component so as not to apply thermomechanical stress to the refractory component under the influence of dimensional changes in the refractory component caused by the nominal operation of the furnace.

15. The furnace as claimed in claim 11, wherein, The surface area of ​​the instrument panel is greater than 20% of the surface area of ​​the fire-resistant component it is attached to.

16. The furnace as claimed in claim 11, wherein, The refractory component is one of the following: - Notched beams or blocks - Lay bricks upright, - Refractory bricks or sidewall blocks -Corner piece, - Filling bricks, - Paving bricks or paving stones - Arched bricks or beams - Blocks or bricks around the air vent - Bricks used for steel tapping or nozzles -Electrode block, -Injector block, - Refractory runner outlet lip plate for glass furnaces - Blocks for injectors -Glass stove notch, - Components for heat exchangers in furnaces - Refractory bricks or plates used for boiler linings - Protective casing for heater tubes in incinerators - Bricks from the incinerator - Ceramic components for solar absorbers - Protective components or bricks used in turbine combustion chambers, - Used for vents or around burners.

17. The furnace as claimed in claim 11, wherein, The measuring device uses the signals it receives from the sensor to provide information relating to the following: -The thickness of the refractory component, or -The average temperature of the furnace, or - The physical state of the refractory components.

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