Anchor system for refractory linings

Abstract

The invention relates to an anchor system for refractory linings, wherein the system comprises: - an anchor having two arms and a bridge part connecting the two arms to each other, - a base structure having a center line, a first end adapted to be connected, for example by welding, to an object, a second end opposite to the first end, and a through-hole crossing the center line and positioned between the first end and the second end, - the anchor and the through-hole are configured for looping the anchor through the through-hole of the base structure during installation.

Description

[0001] Title: Anchor system for refractory linings

[0002] Description:

[0003] The invention relates to an anchor system for refractory linings, wherein the system comprises:

[0004] - an anchor having two arms and a bridge part connecting the two arms to each other,

[0005] - a base structure having a center line, a first end adapted to be connected, for example by welding, to an object, a second end opposite to the first end, and a through-hole crossing the center line and positioned between the first end and the second end,

[0006] - the anchor and the through-hole are configured for looping the anchor through the through-hole of the base structure during installation.

[0007] The invention further relates to a method for installing such an anchor system and to method for maintenance of an installed anchor system.

[0008] US 8 844 239 discloses an anchor system for refractory linings. The known system comprises a fixing device, in which an anchor is held by means of a cap-like clamping element. The clamping element comprises two wings on either side of a beam-shaped central element of the clamping element. The wings are placed by a vertical movement and clamped around two opposite sides of the fixing device such that the clamping element covers in a cap-like manner an end of the fixing device completely.

[0009] It is an object of the present invention to provide an anchor system for refractory linings which can be installed in a relatively user-friendly and quick manner and / or provides improved non-movability of its components with respect to each other after installation in relatively high temperature environments.

[0010] This object is achieved with the anchor system as defined in claim 1.

[0011] The anchor system for refractory linings comprises:

[0012] - at least one anchor having two arms and a bridge part connecting the two arms to each other, - a base structure having a center line, a first end adapted to be connected, for example by welding, to an object, a second end opposite to the first end, and a through-hole crossing the center line and positioned between the first end and the second end,

[0013] - the anchor and the through-hole are configured for looping the anchor through the through-hole of the base structure during installation,

[0014] - at least one heat-resistant connector configured to be moved substantially in a direction traverse to the center line of the base structure from a non-fixation position to a fixation position and vice versa, wherein in the fixation position the connector is adapted to fixate the anchor with respect to the base structure in a non-movable manner.

[0015] By means of the heat-resistant connector configured to be moved substantially in a direction traverse to the center line of the base structure from a non-fixation position to a fixation position and vice versa, the anchor system for refractory linings can be installed in a relatively user-friendly and relatively quick manner with no or at least reduced risk of incorrect placement / installation of the heat-resistant connector in the fixation position. In addition, this movement direction of the heat-resistant connector from a non-fixation position to a fixation position and vice versa makes it also possible that a relatively compact design of the heat-resistant connector can be achieved. An additional advantage of a relatively compact heat-resistant connector is that it is cost-effective to produce by material saving.

[0016] Refractory linings are used in industry for a variety of reasons including thermal insulation, abrasion resistance and general steelwork protection for vessel components in a variety of process applications with relatively high operational temperatures. The refractory lining protects the walls and other components of the vessel / furnace, such as against high temperatures inside the vessel / furnace, which may vary between 500-2000 degrees Celsius, typically around 1200 degrees Celsius. The anchor system after installation is connected / welded by means of the base structure to the object, for example a wall, to be protected. Such an installed anchor system will be or is completely or almost completely submerged in the refractory lining. One of the effects of the refractory lining is that the temperature decreases towards the wall seen in a direction perpendicular to the wall. The wording “heat resistant” in this disclosure means that the heat resistant connector retains strength and form at high operational temperatures starting above 300 degrees, preferably 350 degrees, more preferred 400 degrees and most preferred 500 degrees. The heat resistant connector is preferably made of a non-plastic material, for example made from metal or a metal alloy. After installation and as a result of the configuration of the anchor system, the heat resistant connector will be or is submerged completely in the refractory lining. By providing such a non-deformable heat resistant connector, the non-movability of the components of the anchor system with respect to each other is improved at high operational temperatures. Hence, in the fixation position the connector is adapted to fixate the anchor with respect to the base structure in a nonmovable manner such that after installation of the anchor system the heat-resistant connector fixates the anchor with respect to the base structure independent or relatively independent of the process temperature environment. Non-movability at high operational temperatures between these components of the installed anchor system reduces wear. A further advantage of the heat resistant connector is that after being used for (long-time) fixation, the through-hole of the base structure will not be damaged or at least not be damaged in a manner that the base structure cannot be re-used when for example the anchor of the anchor system has to be replaced. In known anchor systems, the anchor including its holding means are constructed such that for the positioning (during installation) it is held with the desired alignment by means of the holding means with respect to the base structure, but the known holding means are designed to deform or burn out as a result of the relatively high temperatures (for example 200 degrees) after installation, and thus create anchor movability with respect to the base structure in the refractory lining.

[0017] Due to harsh conditions within a furnace, the refractory linings need to be replaced as they deteriorate over time. An advantage of the non-movability characteristics of the anchor system of this disclosure is that the components of the anchor system of this disclosure have relatively long durability, such that no replacement of the anchor system is required during refractory linings replacement. It is also possible that at least the base structure can be re-used during the installation of a renovated anchor system. This already has the advantage that installation times during maintenance of the anchor system can be reduced drastically when it is time to replace the refractory linings, because at least the step of connecting, for example by welding, the base structure to an object can be skipped during maintenance. A further advantage of a relatively compact heat-resistant connector is that after installation the surface area of the heat-resistant connector exposed to refractory lining material is reduced which results in less contact of the connector with the refractory lining. The reduced contact provides less undesired forces on the heat-resistant connector as result of thermal expansions / contradictions of the refractory lining, such that the non-movability characteristics between the components of the anchor system after installation are further optimized. In other words, the heat resistant properties of the connector and its relatively compact dimensions contribute in the desired non- movability effect after installation in the refractory lining. The compact heat-resistant connector may have at least one dimension, for example height, which corresponds to the length of the through-hole, preferably is smaller than the length of the through- hole, more preferably is equal to or smaller than half the length of the through-hole.

[0018] The heat-resistant connector may comprise a non-elastic construction, in that the connector may be construed such that the connector is not able to stretch and return to its original shape or size, or relating to this ability. In this manner the non- movability characteristics of the anchor system as described in this disclosure may be further improved.

[0019] This disclosure also relates to a method for installing the anchor system of this disclosure, comprising the following steps:

[0020] - connecting the first end of the base structure, for example by welding, to the object, for example a metal object;

[0021] - moving the heat-resistant connector substantially in a direction traverse to the center line of the base structure from the non-fixation position to the fixation position, wherein in the fixation position the connector fixates the anchor with respect to the base structure in a non-movable manner, or wherein in the fixation position the anchor is moved, for example rotated, with respect to the connector to fixate the anchor with respect to the base structure in a nonmovable manner.

[0022] This disclosure further relates to a method for maintenance of the installed anchor system, comprising the following steps:

[0023] - moving the heat-resistant connector substantially in a direction traverse to the center line of the base structure from the fixation position to the non-fixation position for disassembling the anchor system; - reusing at least the base structure of the anchor system which remains connected to the object.

[0024] For the sake of brevity and to avoid duplication, the features and / or advantages of these methods are already described above in this disclosure and will not be repeated here.

[0025] It is to be understood that both the foregoing general description and the following detailed description present various embodiments of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. In this disclosure “substantially in a direction traverse to the center line of the base structure” means that the movement between the non-fixation position and the fixation position, or vice versa, forms an angle comprised between 0° and 45° with the center line of the base structure. The center line of the base structure extends in a direction substantially perpendicular to an object to which the base structure is or will be connected.

[0026] The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification.

[0027] The anchor system and method will now be explained in more detail with reference to the appended drawings, in which:

[0028] Figures 1a,b show a first embodiment of the anchor system with its components;

[0029] Figures 2a-c show a components of the anchor system;

[0030] Figures 3a-c show a second embodiment of the anchor system with its components;

[0031] Figure 4a-c shows a third embodiment of the anchor system with its components;

[0032] Figures 5a-c show a fourth embodiment of the anchor system with its components.

[0033] Figure 6 shows base structures with different shaped through-holes;

[0034] Figure 7 shows various base structures with different shaped through-holes.

[0035] The anchor system will now be described more fully hereinafter with reference to the accompanying drawings in which exemplary embodiments of the invention are shown. However, the invention may be embodied in many different forms and should not be construed as limited to the representative embodiments set forth herein. The exemplary embodiments are provided so that this disclosure will be both thorough and complete, and will fully convey the scope of the invention and enable one of ordinary skill in the art to make, use and practice the invention. Like reference numbers refer to like elements throughout the various drawings.

[0036] In figures 1a, 3a, 4a and 5a-c an anchor system 1 ; 101 ; 101’; 201 for refractory linings is shown, the system comprises:

[0037] - an anchor 3; 103; 203 having two arms 3a, 3b; 103a, 103b; 203a, 203b and a bridge part 3c; 103c; 203c connecting the two arms to each other.

[0038] - a base structure 5; 5’; 5”; 105; 105’; 205; 205’; 305 having a center line C, a first end 5a; 105a adapted to be connected, for example by welding, to an object O, a second end 5b; 105b opposite to the first end, and a through-hole 5c; 5c’; 5c”; 105c-305c”” crossing the center line C and positioned between the first end 5a and the second end 5b, In the embodiments shown, the through-hole 5c; 5c’; 5c”; 105c-305c”” is positioned closer to the second end 5b than to the first end 5a. The reference signs for the ends of the base structure are provided in figures 1a-c and figure 3c, and not provided in the other figures showing different kinds of base structures to avoid unnecessary repetition as these ends will be evident.

[0039] - the anchor 3; 103; 203 and the through-hole 5c, are configured for looping the anchor through the through-hole of the base structure during installation,

[0040] - at least one heat-resistant connector 7; 7’; 7”; 107; 107’; 207 configured to be moved in a direction T traverse to the center line C of the base structure 5; 5’; 5”; 105; 105’; 205; 205’; 305 from a non-fixation position (see for example fig. 5a) to a fixation position (see for example fig. 5b) and vice versa (in the opposite direction as indicated with arrow T), wherein in the fixation position the connector is adapted to fixate the anchor with respect to the base structure in a non-movable manner. The heat-resistant connector 7; 107; 107’; 207 shown in the drawings comprises a non-elastic construction.

[0041] The relatively compact heat-resistant connector may have at least one dimension, see for example figures 1a,b the length of the connector 7; 7’; 7” extending in the direction indicated with arrow T, which corresponds to the length of the through- hole 5c , 5c’, 5c”. The compact heat-resistant connector 107, 107’ may also have a height smaller than half the length of the through-hole 105c’ or the compact elongate heat-resistant connector 207 may have a height and a width smaller than half the length of the through-hole 205c.

[0042] The effects and advantages of this anchor system 1 ; 101 ; 10T; 201 are already described above in this disclosure and will not be repeated here.

[0043] The method for installing an anchor system 1 ; 101 ; 10T; 201 comprises at least two or possibly three steps:

[0044] Step 1- connecting the first end 5a of the base structure 5; 5’; 5”; 105; 105’; 205; 205’; 305 to the object O;

[0045] Step 2- moving the heat-resistant connector 7; 7’; 7”; 107; 107’; 207 substantially in a direction traverse T to the center line C of the base structure from the non-fixation position to the fixation position, wherein in the fixation position (fig. 3a, 4a or 5b, c) the connector 107; 107’; 207 fixates the anchor 103; 203 with respect to the base structure 105; 205 in a non-movable manner, or

[0046] Step 3- wherein in the fixation position (fig. 3c) the anchor 3; 103 is moved, for example rotated, with respect to the connector 7; 7’; 7”; 107 to fixate the anchor with respect to the base structure 5; 5’; 5”; 105 in a non-movable manner (fig. 1a, 3a or 4a). The heat-resistant connector 107; 107’ can be installed in a two or three step installation depending on operator preferences.

[0047] This disclosure further relates to a method for maintenance of an installed anchor system, which comprises at least the following two method steps:

[0048] Step 1 - moving the heat-resistant connector 7; 107; 107’; 207 substantially in a direction traverse (opposite direction as indicated by arrow T in the drawings) to the center line C of the base structure 5; 5’; 5”; 105; 105’; 205; 205’; 305 from the fixation position (see for example figs. 1a, 3a, 4a and 5b) to the non-fixation position (see for example fig. 5a) for disassembling the anchor system 1 ; 101 ; 10T; 201 ;

[0049] Step 2 - reusing at least the base structure 5; 5’; 5”; 105; 105’; 205; 205’; 305 of the anchor system 1 ; 101 ; 10T; 201 which remains connected to the object O.

[0050] The base structure 5; 5’; 5”; 105; 105’; 205; 205’; 305 having a center line C can also identified as a bolt. The base structure 5; 5’; 5”; 105; 105’; 205; 205’; 305 may be hand-welded or stud welded to a metal object O, for example a metal vessel wall. The base structure of this disclosure can be secured / connected to the object in any manner, including also for example screwing. The base structure 5; 5’; 5”; 105; 105’; 205; 205’; 305 is designed such that standard anchors 3; 103; 203 can be used, i.e. anchors that can be looped through the through-hole 5c; 5c’; 5c”; 105c-305c””. The arms 3a, 3b; 103a, 103b; 203a, 203b of each anchor 3; 103; 203 may or may not be similar or identical in design, for example the first arm may be shorter or longer than the second arm. In addition many designs are possible for the anchors, see for example the design of anchor 3 and the design of anchor 203. The arms of each anchor 3; 103; 203 are connected by means of a bridge part 3c; 103c; 203c which for installation of the anchor is positioned, at least partly, in the through-hole 5c; 5c’; 5c”; 105c-305c”” of the base structure to obtain an anchor system 1 ; 101 ; 101 ’; 201.

[0051] The first embodiment of the anchor system is shown in fig. 1a, b and variants of the first embodiment are shown in figures 2a-c. The system 1 as shown in figures 1a, b comprises a heat-resistant connector 7 with an introduction part 8 adapted to be introduced inside a “standard” substantially cylindrical through-hole 5c and an antirotation part 9 adapted to be positioned at least partially around the base structure 5 outside the through-hole 5c. The heat-resistant connector 7’; 7” is adapted to be introduced at least partially inside the through-hole 5c’; 5c”. In the variants shown in figures 2a-c the heat-resistant connector 7’; 7” is adapted to be introduced completely or almost completely inside the through-hole 5c’; 5c”. The heat-resistant connector 7’; 7” requires a “non-standard” through-hole 5c’; 5c” in that the heat-resistant connector is provided with an anti-rotation outer shape 9’; 9” adapted to be positioned against or in an anti-rotation counter-shape inside the through-hole 5c’; 5c”. Rotation of the heat-resistant connector 7’ in the through-hole 5c’ after installation is prevented if during installation the anti-rotation outer shape 9’ is moved inside a receiving antirotation counter-shape 6 in a direction T traverse to the center line C of the base structure 5’ from a non-fixation position (fig. 2b) to a fixation position (not shown) and vice versa if desired. Rotation of the heat-resistant connector 7” in the through-hole 5c” is prevented by using complementary shapes having at least one planar side portion or at least one edge (not shown). The heat-resistant connector 7” has four planar sides 9” and the through-hole 5c” has four corresponding planar sides, wherein rotation of the heat-resistant connector 7” after installation is prevented by moving during installation the heat-resistant connector 7” inside the through-hole 5c’ in a direction T traverse to the center line C of the base structure 5’ from a non-fixation position to a fixation position. Each heat-resistant connector 7; 7’; 7” is configured to modify the design of the through-hole 5c, 5c’, 5c’” after insertion therein. As shown in the figures 1a-2c the circular cross section of the through-hole 5c, 5c’, 5c’” is changed by means of the connector 7; 7’; 7” into an oval shaped cross section of the hole of the heat-resistant connector 7; 7’; 7”. In other words, the heat-resistant connector 7; 7’; 7” provides a modified anchor passage in the fixation position. Different shapes (not shown) for the modified anchor passage than an oval shaped cross section are possible. The modified anchor passage is adapted to allow moveability of the anchor 3 in a first anchor orientation, wherein moving the anchor from the first anchor orientation to the second anchor orientation fixates the anchor with respect to the base structure in a non-movable manner as for example shown in figure 1a. With an oval configuration as shown in figures 1a-2c of the connector 7; 7’; 7”, the anchor 3 is rotated approx. 90 degrees between the first anchor orientation and the second anchor orientation. Hence, in the fixation position of the heat-resistant connector 7; 7’; 7” the anchor 3 can be fixated with respect to the base structure 5; 5’; 5” in a non-movable manner by rotating the anchor about a rotation axis. In the embodiments shown in figure 1a-2c the rotation axis is provided by at least a part of the bridge portion 3c of the anchor located inside the through-hole 5c; 5c’; 5c”.

[0052] The embodiments of the anchor system 101 ; 10T shown in figures 3a and 4a have the same working principle. The system 101 differs from system 10T in that different designed base structures 105; 105’ are used and that in system 10T a modified heat-resistant connector 107’ is used with respect to heat-resistant connector 107 in system 101 . This type of heat-resistant connector has, at least partially, a platelike section to be inserted, for example by sliding, in a receiving space 102 of the base structure 105; 105’ for movement of the connector from the non-fixation position to the fixation position. The receiving space of base structure 105’ (fig. 4a) is from a technical perspective identical to the receiving space 102 shown in figure 3b. Between the receiving space 102 and the first end 105a of the base structure 105 the through-hole 105c is provided in the base structure. This configuration is the same for the base structure 105’.

[0053] As shown in figures 4a, b the heat-resistant connector is a plate-shaped heat- resistant connector 107; 107’ with at least one inner circumferential wall surface 112; 112’ defining a cut-out 114; 114’, in particular an open “non-closed” cut-out 114; 114’. The plate-shaped heat-resistant connector 107’ differs from the plate-shaped heat- resistant connector 107 in that at or near at least one of the two corners between the inner circumferential wall surface 112; 112’ and outer wall surface 116’ at least one fixation protrusion 120a, b is provided. Such a protrusion or protrusions 120a, b may facilitate improved fixation in the fixation position of the plate-shaped heat-resistant connector 107; 107’. It is also possible to provide a fixation notch(es) (not shown) instead of protrusion(s) 120a, b, cooperating with a protrusion(s) (not shown) of the base structure.

[0054] The heat-resistant connector 207 of the anchor system 201 is an elongate heat- resistant connector 207 configured to be moved through the through-hole 205c substantially in the direction traverse T to the center line C (fig. 5c) of the base structure 205 from a non-fixation position (fig. 5a) to a fixation position (fig. 5b and 5c) and vice versa, wherein in the fixation position the elongate heat-resistant connector 207 simultaneously fixates the bridging portion 203c of the anchor 203 in the through-hole 205c of the base structure 205 such that the anchor 203 is fixated with respect to the base structure 205 in a non-movable manner. The elongate heat- resistant connector 207 as shown is wedge-shaped which is a compact design and facilitates insertion of the connector 207 into the fixation position. In principle other elongate shapes can be used as long as the connector 207 is at least partially insertable in the through-hole 205c together with the anchor 203. An advantage of a relatively long elongate shape is for example that the connector 207 can be brought from the fixation position to the non-fixation position in a relatively user friendly manner, but is also possible to use a shorter elongate connector than shown in the figures 5a-c, for example with a length (measured in the direction indicated with arrow T) corresponding to the length (measured in the direction indicated with arrow T) of the through-hole 205c. As shown in figures 6 and 7 the through-hole 205c’, 205c”; 305c-305c””” may have any shape or size. A planar receiving surface 202; 202’ as shown in these figures 6 and 7 may facilitate an easy insertion of the elongate connector 207 and a strong connection in the fixation position of the connector 207 between the connector 207 and the through-hole 205c of the base structure 205.

[0055] The heat resistant connector shown in the drawings retains strength and form at high operational temperatures starting above 300 degrees, preferably 350 degrees, more preferred 400 degrees and most preferred 500 degrees. Such a heat resistant connector is preferably made of a non-plastic material, for example made from metal or a metal alloy. The heat resistant connector may be made of stainless steel I plain steel. Ferritic alloys, nickel-based alloys, cobalt-based alloys (or refractory metals) are specific examples of materials of which the heat resistant connector of this disclosure may be made. This specification discloses also at least one heat-resistant connector without the other components of the system, wherein the heat-resistant connector configured to be moved substantially in a direction traverse to the center line of the base structure from a non-fixation position to a fixation position and vice versa, wherein in the fixation position the connector is adapted to fixate the anchor with respect to the base structure in a non-movable manner. Features of the heat-resistant connector as discloses herein and shown in the drawings can be combined with the heat-resistant connector as described in this paragraph.

Claims

CLAIMS1. An anchor system for refractory linings, the system comprises:- an anchor having two arms and a bridge part connecting the two arms to each other,- a base structure having a center line, a first end adapted to be connected, for example by welding, to an object, a second end opposite to the first end, and a through-hole crossing the center line and positioned between the first end and the second end,- the anchor and the through-hole are configured for looping the anchor through the through-hole of the base structure during installation,- at least one heat-resistant connector configured to be moved substantially in a direction traverse to the center line of the base structure from a non-fixation position to a fixation position and vice versa, wherein in the fixation position the connector is adapted to fixate the anchor with respect to the base structure in a non-movable manner.

2. The anchor system according to claim 1 , wherein the heat-resistant connector comprises a non-elastic construction.

3. The anchor system according to claim 1 or 2, wherein the heat-resistant connector has, at least partially, a plate-like section to be inserted, for example by sliding, in a receiving space of the base structure for movement of the connector from the non-fixation position to the fixation position.

4. The anchor system according to claim 3, wherein between the receiving space and the first end of the base structure the through-hole is provided in the base structure.

5. The anchor system according to claim 3 or 4, wherein the plate-like section has at least one inner circumferential wall surface defining a cut-out.

6. The anchor system according to claim 5, wherein at or near at least one of the two corners between the inner circumferential wall surface and outer wall surface of the plate shaped section at least one fixation profusion or fixation notch is provided.

7. The anchor system according to claim 1 or 2, wherein the heat-resistant connector is an elongate heat-resistant connector configured to be moved through the through-hole substantially in the direction traverse to the center line of the base structure from a non-fixation position to a fixation position and vice versa, wherein in the fixation position the elongate heat-resistant connector simultaneously fixates the bridging portion of the anchor in the through-hole of the base structure.

8. The anchor system according to claim 7, wherein the elongate heat-resistant connector is wedge-shaped.

9. The anchor system according to any preceding claim, wherein the heat- resistant connector has at least one dimension, for example height, which corresponds to the length of the through-hole, preferably is smaller than the length of the through- hole, more preferably is equal to or smaller than half the length of the through-hole.

10. The anchor system according to any preceding claim, wherein in the fixation position of the heat-resistant connector the anchor can be fixated with respect to the base structure in a non-movable manner by rotating the anchor about a rotation axis, preferably the rotation axis is provided by at least a part of the bridge portion located inside the through-hole.

11. The anchor system according to claim 10, wherein the heat-resistant connector comprises an introduction part adapted to be introduced inside the through-hole and an anti-rotation part adapted to be positioned at least partially around the base structure outside the through-hole.

12. The anchor system according to claim 10, wherein the heat-resistant connector is adapted to be introduced at least partially inside the through-hole wherein the heat-resistant connector is provided with an anti-rotation outer shape adapted to be positioned against or in an anti-rotation counter-shape inside the through-hole.

13. A method for installing an anchor system according to any preceding claim, comprising the following steps:- connecting the first end of the base structure, for example by welding, to the object, for example a metal object;- moving the heat-resistant connector substantially in a direction traverse to the center line of the base structure from the non-fixation position to the fixation position, wherein in the fixation position the connector fixates the anchor with respect to the base structure in a non-movable manner, or wherein in the fixation position the anchor is moved, for example rotated, with respect to the connector to fixate the anchor with respect to the base structure in a nonmovable manner.

14. A method for maintenance of an installed anchor system according to any preceding claim, comprising the following steps:- moving the heat-resistant connector substantially in a direction traverse to the center line of the base structure from the fixation position to the non-fixation position for disassembling the anchor system;- reusing at least the base structure of the anchor system which remains connected to the object.

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