Coke Oven Corbels or Coke Oven Battery

Abstract

A corbel for a coke oven includes a gun block portion having a vertical through hole disposed therein, the gun block portion having at least one generally vertical through hole communicating with the vertical through hole. The gun block portion may be integral with a base. The gun block portion also includes a generally vertical rectangular channel having an opening at a first end of the gun block portion and an opening at a first side of the gun block portion.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit under Articles 4 and 8 of the Stockholm Act of the Paris Convention for the Protection of Industrial Property of U.S. Provisional Patent Application No. 63 / 262,565, filed on October 15, 2021, and U.S. Provisional Patent Application No. 63 / 262,566, filed on October 15, 2021, which are incorporated herein by reference in their entireties.

[0002] The present invention relates to coke ovens, and more particularly to coke oven corbels. More specifically, the present invention relates to a gun block arrangement for a coke oven corbel or coke oven battery. [Background technology]

[0003] Coke is usually produced by heating coal in a coke oven battery. The battery may contain 40 to 100 or more coke chambers or furnaces installed side by side. These coke chambers or furnaces are separated from each other by heating walls. Gases are burned within the walls to heat the coal placed inside the furnace. The floor bricks of each furnace rest on a corbel. Below the corbel is a regenerator. The regenerator is typically filled with bricks that have a relatively large surface area per volume due to slots cut in the bricks. The regenerator uses waste heat to preheat the incoming air and also cools the waste heat before it is discharged. The slotted bricks are called checker bricks and facilitate the transfer of heat from the exhaust waste heat to the burning material. The regenerator supports the corbels. The corbels support the floor bricks and heating walls of the coke oven. The heating walls, floor bricks, and corbels are traditionally made of silica bricks.

[0004] However, current corbel designs are susceptible to leaks because they are constructed from multiple blocks or modules. Specifically, the modules must be secured together with mortar, which takes time and allows for undesirable thermal expansion. Thermal expansion of the members creates permanent gaps that allow gas leakage. Due to the large number of bricks traditionally used, corbels constructed using traditional techniques and bricks have hundreds, sometimes thousands, of potential failure points.

[0005] Furthermore, current corbel designs do not allow for optimal air flow between the heating walls, particularly the flue and the regenerator. Furthermore, current corbel designs make replacement very difficult and time consuming, requiring the shutdown of the coke process. The corbel component of a coke oven is specifically the gun flue, i.e., a gunfire type coke oven. In gunfire type ovens, the corbel typically has a horizontal gas duct that runs the length of the individual coke oven, known as the "gun block." The gun block is typically a separate piece, surrounded by multiple blocks or modules that collectively form the corbel of the coke oven.

[0006] Thus, there has long been a need for a coke oven corbel that improves air and gas flow between the flue and regenerator and is easily replaceable.

[0007] There has also long been a need for a coke oven corbel having a gun block section that can eliminate the multiple joints caused by multiple blocks or modules fastened around the perimeter of a typical corbel gun block.

[0008] Additionally, there has long been a need for a coke oven corbel having multiple gun block configurations to accommodate different coke oven repair and construction requirements while eliminating the need for extra blocks or modules.

[0009] Additionally, there has long been a need for a corbel construction having an integral gun block, i.e., gun block portion, which would eliminate the need for extra blocks, or modules, to completely construct the corbel, thereby reducing construction and / or repair downtime. Summary of the Invention

[0010] Introduction: The present invention generally relates to a corbel block having multiple gun block configurations. Each configuration includes at least one generally vertical through hole that communicates with a vertical through hole located in a gun block portion of the corbel block. Each of the possible configurations of the present invention can include multiple components extending from and integral with the gun block portion, such as a base, at least one shoulder, at least one ledge, at least one flue channel, or combinations thereof. This allows multiple different configurations to be utilized for repair or construction of coke ovens or coke oven batteries. [Means for solving the problem]

[0011] In some embodiments, the invention generally includes a coke oven corbel including a base, a gun block portion integral with the base and having a longitudinal bore extending from a first end to a second end, at least one generally vertical bore within the gun block portion and in communication with the longitudinal bore, and a pair of shoulders extending from the base, each of the pair of shoulders having a groove defined therein.

[0012] In another embodiment, the invention also generally includes a coke oven corbel including a base having a first side and a second side, a gun block portion integral with the base and having a longitudinal bore extending from a first end to a second end, at least one generally vertical bore in the gun block portion and in communication with the longitudinal bore, and a generally vertical channel proximate the first end of the gun block portion and having an opening in the group consisting of the first base side and the second base side.

[0013] In a further embodiment, the invention generally includes a coke oven corbel including a gun block portion having a longitudinal bore extending from a first end to a second end, the gun block portion having a first side and a second side extending from the gun block portion, at least one generally vertical bore in the gun block portion communicating with the longitudinal bore, and a generally vertical angled channel proximate the first end of the gun block portion and having an opening in the group consisting of the first side and the second side.

[0014] In an additional embodiment, the invention generally includes a coke oven corbel having a first end and a second end, the coke oven corbel having a longitudinal bore extending from the first end to the second end, the gun block portion having at least one generally vertical bore therein, the at least one generally vertical bore communicating with the longitudinal bore, the gun block portion further having at least one arrangement extending therefrom, the arrangement including a base having a first side and a second side extending from the base, the first side having a shoulder disposed thereon, the second side having a shoulder disposed thereon, the base having a first side and a second side extending from the base, and a generally vertical channel proximate the first end of the gun block portion, the generally vertical channel having an opening disposed within the group consisting of: The group includes a first side of the base, a second side of the base, first and second sides extending from the gun block portion, and a generally vertical channel proximate a first end of the gun block portion, the generally vertical channel having an opening disposed within the group of the first and second sides.

[0015] In a further embodiment, the present invention may provide a corbel for a coke oven including a top surface having a first cavity and a second cavity, a bottom surface having a first protrusion extending therefrom, a front surface having a passageway formed therein, a rear surface, a first side surface, a second side surface, and a through hole extending from the front surface to the rear surface, the through hole being in fluid communication with the first cavity and the second cavity.

[0016] In some further embodiments, the second cavity is spaced apart from the first cavity. In some embodiments, at least one of the first cavity and the second cavity is disposed between the first side and the second side and spaced apart from the first side and the second side. In some embodiments, the through hole is at least partially disposed in the first protrusion. In some embodiments, the through hole extends partially above the bottom surface and partially below the bottom surface. In some embodiments, at least one of the first cavity and the second cavity includes a hole extending to the through hole. In some embodiments, the front surface includes a recess disposed around the through hole and the rear surface includes a second protrusion disposed around the through hole. In some embodiments, the passage includes a first end disposed in the first cavity, a second end disposed proximate the bottom surface, a first wall extending from the first end to the second end, and a second wall extending from the first end to the second end. In some embodiments, the first wall and the second wall form a width of the passageway, the width increasing from the first end to the second end. In some embodiments, at least one of the first wall and the second wall includes a curved portion extending from the first cavity and a straight portion extending from the curved portion to the second side. In some embodiments, at least one of the first side and the second side includes a second protrusion extending therefrom in a first direction and spaced apart from the top surface in the second direction, the second direction being perpendicular to the first direction, and a third protrusion extending from the second protrusion in the first direction. In some embodiments, the third protrusion includes a first surface perpendicular to the bottom surface and a second surface tapered from the first surface toward the bottom surface.

[0017] In other additional embodiments, the present invention may provide a corbel for a coke oven, comprising: a first side, a second side, a top surface having a first cavity and a second cavity, a bottom surface having a first protrusion extending therefrom, a front surface including a passage formed therein, the passage extending along a curve from the first cavity to the second side surface, a rear surface, and a through hole extending from the front surface to the rear surface, the through hole being in fluid communication with at least one of the first cavity and the second cavity.

[0018] In yet additional embodiments, the second cavity is spaced apart from the first cavity. In some embodiments, the through hole is at least partially disposed on the first protrusion. In some embodiments, at least one of the first cavity and the second cavity includes a hole extending to the through hole. In some embodiments, the passage includes a first end disposed in the first cavity, a second end disposed proximate the bottom surface, a first wall extending from the first end to the second end, and a second wall extending from the first end to the second end. In some embodiments, the first wall and the second wall form a width of the passage, the width increasing from the first end to the second end. In some embodiments, at least one of the first side and the second side includes a second protrusion extending therefrom in a first direction, the second protrusion spaced apart from the top surface in a second direction, the second direction being perpendicular to the first direction, and a third protrusion extending from the second protrusion in the first direction.

[0019] In yet an additional embodiment, the present invention may provide a coke oven battery including a regenerator having a regenerator region formed between a plurality of struts, and a corbel disposed on at least one of the plurality of struts, the corbel including a top surface having a first cavity and a second cavity, a bottom surface having a first protrusion extending therefrom and engaging the at least one strut, a front surface having a passage formed therein, a rear surface, a first side surface, a second side surface, a through hole extending from the front surface to the rear surface and in fluid communication with the first cavity and the second cavity, a heating wall at least partially disposed on the top surface and including at least one flue in fluid communication with at least one of the first cavity, the second cavity, and the passage, and a floor engaging at least one of the first side surface and the second side surface. [Problem to be solved by the invention]

[0020] It is an object of the present invention to provide a corbel having an integrally disposed gun block portion with multiple components extending therefrom, which may be utilized in the construction and / or repair of coke oven batteries, thereby eliminating the need for additional blocks, bricks, and / or modules, thereby providing: 1. fewer seams to prevent potential leaks; 2. fewer components during construction and / or repair by combining traditionally used blocks, modules, and / or bricks into an integral corbel having multiple configurations; and 3. more efficient construction and / or repair by eliminating the need for additional components in the assembly of coke ovens and / or coke oven batteries.

[0021] These and other objects, features and advantages of the present invention will become readily apparent from a review of the following detailed description of the invention, taken in conjunction with the drawings and the appended claims. [Brief description of the drawings]

[0022] Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which: [Figure 1] FIG. 1 is an exemplary cross-sectional view of a coke oven battery according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is a partial perspective view of the coke oven battery shown in FIG. [Figure 3A] FIG. 3A is a perspective view of the first embodiment of the corbel shown in FIG. [Figure 3B] FIG. 3B is a skeletal perspective view of the corbel shown in FIG. 3A. [Figure 3C] FIG. 3C is a perspective view of an alternative embodiment of the corbel shown in FIGS. 3A and 3B. [Figure 3D] FIG. 3D is a top view of the two corbels shown in FIG. 3C. [Figure 4]FIG. 4 is an exemplary cross-sectional view of a coke oven battery according to a second embodiment of the present invention. [Diagram 5] FIG. 5 is a partial perspective view of the coke oven battery shown in FIG. [Figure 6A] FIG. 6A is a perspective view of a second embodiment of the corbel shown in FIG. [Figure 6B] FIG. 6B is a skeletal perspective view of the corbel shown in FIG. 6A. [Figure 6C] FIG. 6C is a perspective view of an alternative embodiment of the corbel shown in FIGS. 6A and 6B. [Figure 6D] FIG. 6D is a skeletal perspective view of the corbel shown in FIG. 6C. [Figure 6E] FIG. 6E is a perspective view of two corbels shown in FIG. 6A with alternating channels. [Figure 6F] FIG. 6F is a top view of the two corbels shown in FIG. 6E. [Figure 7] FIG. 7 is an exemplary cross-sectional view of a coke oven battery according to a third embodiment of the present invention. [Figure 8] FIG. 8 is a partial perspective view of the coke oven battery shown in FIG. [Figure 9A] FIG. 9A is a perspective view of a third embodiment of the corbel shown in FIG. [Figure 9B] FIG. 9B is a skeletal perspective view of the corbel shown in FIG. 9A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] At the outset, it should be understood that like drawing numbers on different drawings identify identical or functionally similar structural elements. It should be understood that the claims are not limited to the disclosed aspects.

[0024] It is further understood that the disclosure is not limited to the particular methodology, materials, and modifications described, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the claims.

[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It should be understood that any methods, devices, or materials similar or equivalent to those described herein may be used in the practice or testing of the exemplary embodiments. The assemblies of the present disclosure may be hydraulically, electronically, pneumatically, and / or spring-driven.

[0026] It should be understood that the term "substantially" is synonymous with terms such as "approximately," "almost," "about," "very close," "periphery," "boundary," "neighborhood," "essentially," "proximal," "vicinity," and the like, and such terms may be used interchangeably as they appear in the specification and claims. It should be understood that the term "proximate" is synonymous with terms such as "neighborhood," "close," "adjacent," "immediate," "vicinity," and the like, and such terms may be used interchangeably as they appear in the specification and claims. The term "about" is intended to mean a value within 10% of a specified value.

[0027] The use of "or" in this application should be understood to refer to a "non-exclusive" configuration unless otherwise stated. For example, when it says "item x is A or B," it is understood that this can mean either of the following: (1) item x is either A or B, and only; (2) item x is both A and B. The term "or" is not used to define an "exclusive or" configuration. For example, an "exclusive or" configuration for the sentence "item x is A or B" requires that x can be either A or B, and only. Furthermore, as used herein, "and / or" is intended to mean a grammatical conjunction used to indicate that one or more of the described elements or conditions may be included or occur. For example, a device consisting of a first element, a second element and / or a third element is intended to be construed as any one of the following structural configurations: a device consisting of a first element; a device consisting of a second element; a device consisting of a third element; a device consisting of a first element and a second element; a device consisting of a first element, a second element and a third element; or a device consisting of a second element and a third element.

[0028] Furthermore, as used herein, the phrases "comprises" and "comprising" in conjunction with a system or element are intended to mean that the system or element includes one or more of the elements listed after the phrase. For example, "an apparatus including at least one of a first element; a second element; and a third element" is intended to be interpreted as any one of the following structural configurations: an apparatus including a first element; an apparatus including a second element; an apparatus including a third element; an apparatus including a first element and a second element; an apparatus including a first element and a third element; an apparatus including a first element, a second element, and a third element; or an apparatus including a second element and a third element. A similar interpretation is intended when the phrase "used in at least one of" is used herein.

[0029] It should be noted that the term "channel" (used in accordance with the components designated with reference numerals 40, 250, and 350) is substantially the same as the expression "vertical angle channel." Therefore, the terms can be used interchangeably. However, it should also be noted that the component designated with reference numeral 40 is not a component of the present invention, while the components designated with reference numerals 250 and 350 are.

[0030] It should also be noted that the term "vertical through hole" is used in accordance with the components designated by reference numerals 42, 110, 110A, 110B, 210A, 210B, 310A, and 310B. However, it should be further noted that the component designated by reference numeral 42 is not a component of the present invention, while the components designated by reference numerals 110, 110A, 110B, 210A, 210B, 310A, and 310B are.

[0031] (Coke Oven Battery) Referring now to the figures, the following description should be made in view of Figures 1-2, 4-5 and 7-8, which generally show a cross-sectional view of a coke oven battery and a partial perspective view thereof, respectively. Specifically, Figures 1 and 2 generally illustrate a coke oven battery (corbel 100) having a first embodiment of the present invention therein, Figures 4 and 5 generally illustrate a coke oven battery (corbel 200) having a second embodiment of the present invention therein, and Figures 7 and 8 generally illustrate a coke oven battery (corbel 300) having a third embodiment of the present invention therein. The foregoing illustrations generally depict the same components of a coke oven battery with few structural differences provided by alternative structural configurations of various embodiments of the present invention. It should be noted that these illustrations of the coke oven battery 10 are merely exemplary and one skilled in the art would understand that Figures 1-2, 4-5 and 7-8 are merely representative to illustrate the structural advantages of utilizing the corbels 100, 200 and 300 therein.

[0032] 1, 4 and 7 are cross-sectional views of a coke oven battery 10 in accordance with co-bels 100, 200 and 300, respectively. The coke oven battery 10 generally includes a regenerator 20 and one or more furnaces 34.

[0033] The regenerator 20 includes a plurality of piers or columns 22 spaced apart to form a regenerator region 24. In some embodiments, each of the columns 22 includes a plurality of bricks, modules, and / or blocks. A base 26 is disposed on the columns 22. The base 26 generally supports, directly or indirectly, the corbels 100, 200, and 300. Generally, the base 26 includes a plurality of bricks, modules, and / or blocks, i.e., various structural components. In some embodiments, the base 26 includes a plurality of blocks arranged in multiple layers, for example, two layers T1 and T2 as shown in FIG. 1 and FIG. 4, or four layers T1-4 as shown in FIG. 7.

[0034] The corbels 100, 200, 300 are positioned on the columns 22 and support the furnace portion of the coke oven battery 10. Specifically, the corbels 100, 200, and 300 support the floor 28, the heating walls 30, and the coal disposed within the furnace 34, allow air to flow between the flue 32 and the regenerator 20, and allow gas to be injected into the flue 32. For example, gas is injected horizontally into corbels 100, 200, and 300 through horizontal through-holes 105, 205, and 305 in gun block sections 101, 102, and 103, respectively, and flows vertically through vertical through-holes 110 and 42 (vertical through-hole 42 is not a component of corbel 100, but is in fluid communication with vertical through-hole 110), 210A and 210B (vertical through-holes of corbel 200), and 310A and 310B (vertical through-holes of corbel 300) to flue 32. As described herein, corbel 100 can have a pair of vertical through-holes 110A and 110B (shown in FIGS. 2 and 3C) in fluid communication with vertical through-hole 42 of coke oven battery 10 (shown in FIG. 2). The air flows through channels 40, 250 (channels of corbel 200) and / or 350 (channels of corbel 300) into the flue 32 where it mixes with the fuel and burns, heating the heating wall 30 and burning the coal located in the furnace 34 into coke. Such combustion produces exhaust gases, which flow down through channels 40 (channels of the coke oven battery 10 if corbel 100 is used therein), 250 (channels of corbel 200) and 350 (channels of corbel 300) into the regenerator region 24, thereby preheating the incoming gas and / or air. Preheating the gas and / or air as it flows into the flue prior to combustion is desirable as it results in more efficient vaporization and higher combustion efficiency than cold fuel. It will be understood by those skilled in the art that in some arrangements, the coke oven battery 10 further comprises shutoff means (not shown) operably arranged to selectively shut off gas flow through one or more of the vertical through-holes.Since perforations 110 (perforations of corbel 100), 110A and 110B (perforations of alternatively configured corbel 100), 210A and 210B (perforations of corbel 200), and 310A and 310B (perforations of corbel 300) are preferably associated with different flues 32, such shutoff means (e.g., valves) allow an operator to control the temperature within each flue 32 and, therefore, furnace 34. Corbels 100, 200, and 300 are described in further detail below.

[0035] The floor 28 is disposed (directly or indirectly) on and / or engages the corbels 100, 200, and 300. The floor 28 is operatively positioned to support coal in the furnace 34. In some embodiments, the floor 28 comprises a plurality of blocks. The floor 28 can also include a plurality of blocks arranged in a plurality of layers, for example, six layers T4-9 in FIG. 1 and three layers T7-9 in FIG. 4 and FIG. 7. The heating wall 30 is disposed on the corbels 100, 200, 300 and / or the floor 28 and includes a flue 32 disposed therein. The flue 32 is in fluid communication with the through hole 110 (through hole of the corbel 100 via the vertical through hole 42), 210A and 210B (through holes of the corbel 200), 310A and 310B (through holes of the corbel 300), and the channels 40, 250, and 350. The furnace ceiling or ceiling 36 is disposed adjacent to or above the heating wall 30. Thus, the coke oven 34 is formed by the floor 28, the heating wall 30, and the furnace ceiling 36. The battery top 38 may be disposed above the heating wall 30 and surround the flues 32. In some embodiments, each flue 32 is in fluid communication with one channel (40, 250 and / or 350) and at least one vertical through-hole, e.g., vertical through-holes 42, 210A and / or 310A. In some embodiments, and as shown in Figures 4 and 7, each flue 32 is in fluid communication with the vertical through-hole 210A or 310A, the vertical through-hole 210B or 310B (of the adjacently disposed corbel), and one channel (250 or 350). Specifically, one flue 32 is aligned in order in direction D3 with vertical through hole 210B (or 310B) of the first corbel, channel 250 (or 350) of a second corbel disposed adjacent to the first corbel, and vertical through hole 210A (or 310A) of the second corbel. As discussed above and shown in FIG. 2, it should be understood that corbel 100 may alternatively be arranged to have two vertical through holes and be limited to the aforementioned arrangement that does not include a channel within corbel 100, i.e., channel 40 is not a component of corbel 100 as shown in FIGS. 1 and 2.

[0036] The arrangement with gas injection holes on either side of the air injection passage provides the desired combustion mixing of air and fuel. In some configurations, as shown in Figures 4 and 7, the heating wall 30 may be disposed only on the upper surface, i.e., the top surface, of the corbels 200 and 300. In some embodiments, the heating wall 30 may be disposed at least partially on the corbels 200 and 300 and may be disposed at least partially on the floor 28. In some embodiments, the heating wall 30 may be disposed only on the floor 28.

[0037] (Corbel: First embodiment) The following description is directed to a first embodiment of the present invention and should be taken into consideration with Figures 1 to 3D, which respectively show a cross-sectional view, a partial perspective view, a front perspective view, and a skeleton perspective view of a coke oven battery according to corbel 100, an alternative embodiment of corbel 100, and a top view of corbel 100 and an adjacent corbel 100.

[0038] Corbel 100 generally includes a gun block portion 101, a base portion 102, a top end 102A, a first end 103, a second end 104, a throughbore 105 having a first opening 106 and a second opening 107, a first side 108, a second side 109, and a vertical throughbore 110. Gun block portion 101 has a horizontal gas line, throughbore 105, defined by a first opening 106 disposed within first end 103 and a second opening 107 disposed within second end 104. Vertical throughbore 110 is in fluid communication with throughbore 105 and has an opening disposed within top end 102A.

[0039] First side 108 is defined by a tapered section 120A extending from base 102. Tapered section 120A terminates at a shoulder 122A. Extending from shoulder 122A is a first side 124A of gun block section 101. Groove 126A is disposed within shoulder 122A and is positioned to extend from first end 103 to second end 104.

[0040] The second side 109 is defined by a tapered section 120B extending from the base 102. The tapered section 120B terminates at a shoulder 122B. Extending from the shoulder 122B is a first side 124B of the gun block section 101. A groove 126B is disposed within the shoulder 122B and is positioned to extend from the first end 103 to the second end 104.

[0041] In an alternative embodiment of corbel 100 shown in FIG. 3C, corbel 100 can have a first vertical through hole 110A and a second vertical through hole 110B, each of through holes 110A and 110B having an opening disposed within upper end 102A and both being in fluid communication with through hole 105.

[0042] In some embodiments, the through hole 105 includes a recess 106A and a lip 107A, with the recess 106A disposed proximate the first opening 106 and the lip 107A extending from the second opening 107. As generally shown in FIG. 3D, the lip 107A of the corbel 100 is disposed to seat within the recess 106A of the adjacent corbel 100', thereby forming a more efficient seal between the through hole 105 of the corbel 100 and the through hole 105 of the adjacent corbel 100', thereby preventing and / or limiting gas leakage therebetween. It should be understood that the above-described arrangement of the through hole 105 of the corbel 100 and the through hole 105 of the adjacent corbel 100' may also be applied to the corbels 200 and 300 (shown in FIG. 9A) to thereby prevent and / or limit gas leakage therebetween.

[0043] It should be appreciated that an important aspect of the corbel 100 is the configuration that provides layers between the base 26 and the floor 28, specifically layer (T3) adjacent the base 26, and a portion of layer T4, as shown in Figures 1 and 2. Specifically, the corbel 100 provides layers T3 and a portion of layer T4 in an integrally formed single block. By providing a portion of layer T4 and the base 26 (which may include layer T3), a stronger and easier connection is formed between the corbel 100 and the base 26. In some embodiments, the base 102 of the corbel 100 can also have layers T1 and T2, thereby eliminating the need for the base 26, as shown in Figure 1.

[0044] It should further be appreciated that grooves 126A and 126B provide mating locations for respective protrusions disposed on the undersides of blocks (layer T4) disposed on shoulders 122A and 122B, thereby preventing displacement of those blocks in directions D5 and D6, i.e., similar to a tongue and groove connection. In some embodiments, grooves 126A and 126B can have vertically disposed portions extending therefrom, i.e., a cross shape, further preventing displacement of blocks disposed thereon in directions D3-D6.

[0045] It should also be appreciated that tapered portions 120A and 120B of corbel 100 assist in directing air into channel 40 (i.e., air traveling in direction D1) when positioned next to tapered portions 120A and 120B of an adjacent corbel 100. It should also be appreciated that in some embodiments, corbel 100 may not include tapered portions 120a and 120b, while sides 108 and 109 are substantially planar surfaces that extend to base 102.

[0046] (Corbel: Second embodiment) The following description is directed to a second embodiment of the present invention and reference is made to Figures 4-6F which show a cross-sectional view, a partial perspective view, a front perspective view and a skeleton perspective view of a coke oven battery according to a corbel 200. Figures 4-6F respectively show a perspective view of an alternative embodiment of a corbel 200, a skeleton perspective view of an alternative embodiment of a corbel 200, a perspective view of two adjacent corbels 200 with alternating channels, and a top view of two adjacent corbels 200 with alternating channels.

[0047] Corbel 200 generally includes gun block portion 201, base 202, top end 202A, first end 203, second end 204, through hole 205 having first opening 206 and second opening 207, first side 208, second side 209, first vertical through hole 210A, second vertical through hole 210B, and channel 250. Gun block portion 201 has a horizontal gas line, through hole 205, defined by first opening 206 disposed within first end 203 and second opening 207 disposed within second end 204. First vertical through hole 210A and second vertical through hole 210B are in fluid communication with through hole 205 and both have openings disposed within top end 202A. Specifically, the openings of the first vertical through-hole 210A and the second vertical through-hole 210B are disposed within recesses 230A and 230B, respectively, that are disposed within the top end 202A.

[0048] The first side 208 is defined by a tapered portion 240A extending from the base 202. The tapered portion 240A terminates at a first planar end 241A. The first planar end 241A terminates at a first ledge portion 242A. A second planar end 243A extends from the first ledge portion 242A. The second planar end 243A terminates at a second ledge portion 244A. A third planar end 245A extends from the second ledge portion 244A. The third planar end 245A terminates at the top end 202A.

[0049] The second side 209 is defined by a tapered portion 240B extending from the base 202. The tapered portion 240B terminates at a first planar end 241B. The first planar end 241B terminates at a first ledge portion 242B. A second planar end 243B extends from the first ledge portion 242B. The second planar end 243B terminates at a second ledge portion 244B. A third planar end 245B extends from the second ledge portion 244B. The third planar end 245B terminates at the top portion 202A.

[0050] The channel 250 is disposed within the first end 203 of the corbel 200 and has an opening on the first end 203. The channel 250 has two ends, a first end disposed within the recess 230A and a second end disposed within the tapered portion 240A, the first flat end 241A, and the first ledge portion 242A of the first side 208. It should be understood that the channel 250 may alternatively be disposed such that its second end is disposed within the second side 209 of the corbel 200 (i.e., within the tapered portion 240B, the first flat end 241B, and the first ledge portion 242B), as shown in Figures 6E and 6F. It should be noted that the aforementioned configurations and alternating channels may also be applied to the corbel 300. As generally shown in FIG. 6F, the opening of the channel 250 (located at the first end 203) is positioned to be closed, covered and / or sealed by the second end 204 of an adjacent corbel 200' that is adjacent to the first end 203 of the corbel 200 having the channel 250 therein.

[0051] In some embodiments, the channel 250 may not include an opening disposed within the first end 203. As shown in Figures 6C and 6D, the channel 250 may be disposed within the corbel 200. The corbel 200 may be utilized as an end corbel or bookend for multiple corbels that are butted together. The above configurations may also be applied to the corbel 300.

[0052] It should be appreciated that an important aspect of the corbel 200 is the configuration that provides layers between the base 26 and the floor 28, specifically layers (T3 and T4) adjacent the base 26, as well as layers (T5 and T6) adjacent the floor 28, as shown in Figures 4 and 5. Specifically, the corbel 200 provides layers T3 through T6 in a single, integrally formed block, providing a stronger and easier connection between the corbel 200 and the base 26 and eliminating the seams created by the individual blocks. The corbel 200 also provides a portion of layers T7-T9. In some embodiments, the base 202 of the corbel 200 can also have layers T1 and T2, thereby eliminating the need for the base 26, as shown in Figure 4.

[0053] Layer T7 is positioned to be supported by first ledge portion 242A (and / or first ledge portion 242B). Specifically, each block of layer T7 is placed on first ledge portion 242A (and / or first ledge portion 242B) and is positioned to abut second planar end 243A (and / or second planar end 243B), which prevents the blocks of layer T7 from moving in direction D5 or D6.

[0054] The floor 28 of layers T8 and / or T9 is arranged to be supported by the second ledge portion 244A (and / or the second ledge portion 244B). The respective block or blocks of the floor 28 are specifically placed on the second ledge portion 244A (and / or the second ledge portion 244B) and are arranged to abut the third planar edge 245A (and / or the third planar edge 245B), which prevents the respective block or blocks of the floor 28 (layers T8 and / or T9) from moving in the direction D5 or D6.

[0055] The arrangement of the corbels 200 allows the various layers of the floor 28 to be engaged and supported at different locations. This not only increases the support strength of the floor 28, but also makes it easier to repair the floor 28. Over time, damage occurs to the floor 28, for example, due to the loading and unloading of coal / coke from the furnace 34. Typically, this damage occurs in the top layer of the floor, i.e., layer T9. The design of the corbels 200 (i.e., supporting two or more layers of the floor 28) allows layer T9 to be easily removed and a new layer T9 to be placed without removing other layers of the floor 28. Not having to replace the entire floor 28 saves downtime of the battery 10 and labor costs.

[0056] Corbel 200 typically comprises layers T3-T6 and some layers T7-T9, eliminating existing seams created by the multiple blocks that once comprised these layers, thereby eliminating potential leak points for gas and heat.

[0057] (Corbel: Third embodiment) The following description relates to the third embodiment of the present invention, and please refer to Figures 7 to 9B which respectively show a cross-sectional view, a partial perspective view, a front perspective view, and a skeleton perspective view of a coke oven battery relating to a corbel 300.

[0058] Corbel 300 generally includes gun block portion 301, upper end 302A, lower end 302B, first end 303, second end 304, through hole 305 having first opening 306 and second opening 307, first side 308, second side 309, first vertical through hole 310A, second vertical through hole 310B, and channel 350. Gun block portion 301 includes a horizontal gas line, through hole 305, defined by first opening 306 disposed within first end 303 and second opening 307 disposed within second end 304. First vertical through hole 310A and second vertical through hole 310B are in fluid communication with through hole 305 and both have openings disposed within top end 302A. Specifically, the openings of the first vertical through-hole 310A and the second vertical through-hole 310B are located within recesses 330A and 330B, respectively, disposed within the top end 302A.

[0059] The first side 308 is defined by a tapered portion 340A terminating at a first planar end 341A. The first planar end 341 terminates at a first ledge portion 342A. A second planar end 343A extends from the first ledge portion 342A. The second planar end 343A terminates at a second ledge portion 344A. A third planar end 345A extends from the second ledge portion 344A. The third planar end 345A terminates at the top end 302A. The first side 308 also has a base 360A disposed adjacent the bottom end 302B. A protrusion 362A extends from the base 360A and is disposed to extend along the base 360A from the first end 303 to the second end 304.

[0060] The second side 309 is defined by a tapered portion 340B that terminates at a first planar end 341B. The first planar end 341B terminates at a first ledge portion 342B. A second planar end 343B extends from the first ledge portion 342B. The second planar end 343B terminates at a second ledge portion 344B. A third planar end 345B extends from the second ledge portion 344B. The third planar end 345B terminates at the top end 302A. The second side 309 also has a base 360B disposed adjacent the bottom end 302B. A protruding portion 362B extends from the base 360B and is further disposed to extend along the base 360B from the first end 303 to the second end 304.

[0061] The channel 350 is disposed within the first end 303 of the corbel 300 and has an opening on the first end 303. The channel 350 has two ends, a first end disposed within the recess 330A and a second end disposed within the tapered portion 340A, the first flat end 341A, and the first ledge portion 342A of the first side 308. It should be understood that the channel 350 may alternatively be disposed such that its second end is disposed within the second side 309 (i.e., within the tapered portion 340B, the first flat end 341B, and the first ledge portion 342B). The opening of the channel 350 is disposed to be closed and / or sealed by the second end 304 of the corbel 300 adjacent the first end 303 of the corbel 300 having the channel 350 therein. Alternatively, the channels 350 may be disposed in the corbel 300 in a substantially similar arrangement as the channels 250 of the corbel 200 illustrated in FIG. 6E.

[0062] It should be noted that protrusions 362A and 362B are operatively positioned to engage recesses in base 26. The engagement between protrusions 362A and 362B and recesses in base 26 aids in aligning and securing corbel 300 during installation. Protrusions 362A and 362B form part of layer T4 and engage layer T4 of base 26, as shown in FIG. 7. The location of protrusions 362A and 362B extending from bases 360A and 360B to engage base 26 provides additional securing of corbel 300 to base 26. Protrusions 362A and 362B increase the surface area over which corbel 300 can be secured to base 26, further eliminating misalignment of corbel 300 in directions D5 and D6.

[0063] It should be appreciated that an important aspect of corbel 300 is that its construction provides an intermediate layer between base 26 and floor 28, as well as a portion of layer T4 and possibly layer T3 (as shown in FIG. 7). Specifically, corbel 300 provides layers T4-6 in a single, integrally formed block. By providing a portion of layer T4, i.e., base 26, a stronger and easier connection is made between corbel 300 and base 26.

[0064] Layer T7 is positioned to be supported by first ledge portion 342A (and / or first ledge portion 342B). Each block of layer T7 is specifically positioned to rest on first ledge portion 342A (and / or first ledge portion 342B) and abut against second planar end 343A (and / or second planar end 343B), which prevents the blocks of layer T7 from moving in direction D5 or D6.

[0065] The floor 28 of layers T8 and / or T9 is arranged to be supported by the second ledge portion 344A (and / or the second ledge portion 344B). The respective block or blocks of the floor 28 are specifically placed on the second ledge portion 344A (and / or the second ledge portion 344B) and are arranged to abut the third planar edge 345A (and / or the third planar edge 345B), which prevents the respective block or blocks of the floor 28 (layers T8 and / or T9) from moving in the direction D5 or D6.

[0066] The arrangement of the corbels 300 allows the various layers of the floor 28 to be engaged and supported at different locations. This not only increases the support strength of the floor 28, but also makes it easier to repair the floor 28. Over time, damage occurs to the floor 28, for example, due to the loading and unloading of coal / coke from the furnace 34. Typically, this damage occurs in the top layer of the floor 28, i.e., layer T9. The design of the corbels 300 (i.e., supporting two or more layers of the floor 28) allows layer T9 to be easily removed and a new layer T9 to be placed without removing other layers of the floor 28. Not having to replace the entire floor 28 saves downtime of the battery 10 and labor costs.

[0067] Corbel 300 is generally constructed from layers T5 and T6 and portions of layers T4 and T7-T9, eliminating existing seams created by the multiple blocks that once comprised these layers and potential leak points for gas and / or heat.

[0068] The following description should be made with all the above figures in mind. Tapered sections 120A and 120B (tapered section of corbel 100), tapered sections 240A and 240B (tapered section of corbel 200), and tapered sections 340A and 340B (tapered section of corbel 300) when combined with the tapered sections of adjacent corbels form a V-shape. This V-shaped configuration forces air traveling in direction D1 to flow into channel 40 (channel of coke oven 10 with corbel 100 therein), channel 250 (channel of corbel 200), and channel 350 (channel of corbel 300).

[0069] In a preferred embodiment, the horizontal through-holes of the gun block portions of each of the corbels 100, 200, 300 have first and second ends defined by respective openings. One of the openings has a recess and the opposing opening has a lip or protrusion extending therefrom. The recess and lip are positioned to facilitate connection between the two corbels while the lip of the horizontal through-hole is positioned to fit within the recess of the horizontal through-hole of the adjacently positioned corbel as described above. This arrangement provides a tight seal for fluid communication of the horizontal through-holes of the respective gun block portions.

[0070] It will be understood that various aspects and other features and functions of the invention, or alternatives thereof, may be desirably combined into many other different systems or applications. Various alternatives, modifications, variations, or improvements not presently foreseen or anticipated may subsequently be made by those skilled in the art which are also intended to be encompassed by the following claims. [Explanation of symbols]

[0071] 10 Coke Oven Battery 20 Regenerator 22 Pier or Pillar 24 Play area 26 Base 28th Floor 30 Heated Wall 32 Flue 34 Furnace 36 Furnace roof 38 Battery Top 40 Coke Oven Battery 10 Channels 42 Vertical through hole of coke oven battery 10 100 Corbel 101 Gun block part of Corbel 100 102 Base of Corbel 100 102A Upper end of corbel 100 103 First end of corbel 100 104 Second end of corbel 100 105 Through hole of gun block portion 101 106 First opening of through hole 105 106A Recess of first opening 106 107 Second opening of through hole 105 107A Lip portion of second opening 107 108 Corbel 100 first side 109 Second side of Corbel 100 110 Vertical through hole of gun block portion 101 120A Tapered portion of side surface 108 120B Tapered portion of side surface 109 122A Shoulder of side 108 122B Shoulder of side 109 124A First side of gun block portion 101 124B second side of gun block portion 101 126A Groove in shoulder 122A 126B Groove in shoulder 122B 200 Corbel 201 Gun block part of Corbel 200 202 Base of Corbel 200 202A Upper end of corbel 200 203 First end of corbel 200 204 Second end of corbel 200 205 Through hole of gun block part 201 206 First opening of through hole 205 206A Recess of first opening 206 207 Second opening of through hole 205 207A Lip portion of second opening 207 208 First side of Corbel 200 209 Second side of Corbel 200 210A First vertical through hole of gun block portion 201 210B second vertical through hole of gun block portion 201 230A First recess in upper end 202A 230B Second recess in upper end 202A 240A Tapered portion of side surface 208 240B Tapered portion of side surface 209 241A first flat end of side surface 208 241B First flat end of side surface 209 242A First ledge of side 208 242B First ledge of side 209 243A second flat end of side surface 208 243B second flat end of side surface 209 244A Second ledge of side 208 244B Second ledge of side 209 245A Third Planar End of Side 208 245B Third flat end of side surface 209 250 Corbel 200 Channel 300 Corbel 301 Gun block part of Corbel 300 302A Upper end of corbel 300 302B Bottom end of corbel 300 303 First end of corbel 300 304 Second end of corbel 300 305 Through hole of gun block part 301 306 First opening of through hole 305 307 Second opening of through hole 305 308 First side of Corbel 300 309 Second side of Corbel 300 310A First vertical through hole of gun block part 301 310B Second vertical through hole of gun block portion 301 330A First recess in upper end 302A 330B Second recess in upper end 302A 340A Tapered part of side 308 340B Tapered part of side 309 341A first flat end of side 308 341B First flat end of side surface 309 342A First ledge of side 308 342B First ledge of side 309 343A second flat end of side 308 343B second flat end of side 309 344A Second ledge of side 308 344B Second ledge of side 309 345A third planar end of side 308 345B Third flat end of side 309 350 Corbel 300 Channel 360A Base of side 308 360B Base of side 309 362A Protrusion of base 360A 362B Protrusion of base 360B D1 direction D2 direction D3 Direction D4 direction D5 direction D6 direction T1 layer T2 layer T3 layer T4 layer T5 layer T6 layer T7 layer T8 layer T9 layer

Claims

1. A coke oven corbel, a base having a first side and a second side; a gun block portion integral with the base portion and having a vertical through hole extending from a first end to a second end; at least one substantially vertical through hole provided in the gun block portion and communicating with the vertical through hole; a generally angular channel adjacent the first end of the gun block portion; The generally angular channel has an opening disposed within the group consisting of the first side of the base and the second side of the base.

2. 2. The coke oven corbel of claim 1, wherein the vertical through hole includes a recess proximate the first end of the gun block portion, and the vertical through hole includes a lip extending therefrom and positioned proximate the second end of the gun block portion.

3. The coke oven corbel according to claim 2 , wherein the recess of the vertical through-hole is arranged to receive a lip portion of the vertical through-hole of an adjacent corbel.

4. 2. The coke oven corbel of claim 1, wherein the first side of the gun block portion includes at least one ledge portion, the second side of the gun block portion includes at least one ledge portion, the at least one ledge portion on the first side being positioned to receive a block thereon, and the at least one ledge portion on the second side being positioned to receive a block thereon.

5. 2. The coke oven corbel of claim 1, wherein the substantially vertical channel is closed by a second end of an adjacent corbel positioned adjacent to the first end of the corbel.

6. a gun block portion having a longitudinal through bore extending from a first end to a second end, the gun block portion having a first side surface and a second side surface extending therefrom; at least one substantially vertical through hole provided in the gun block portion and communicating with the vertical through hole; a generally angular channel adjacent the first end of the gun block portion; The generally angular channel has an opening disposed within the group consisting of the first side and the second side.

7. 7. The coke oven corbel of claim 6, wherein the vertical through hole includes a recess proximate the first end of the gun block portion, and the vertical through hole has a lip extending therefrom and positioned proximate the second end of the gun block portion.

8. The coke oven corbel according to claim 7 , wherein the recess of the vertical through-hole is arranged to receive a lip portion of the vertical through-hole of an adjacent corbel.

9. 7. The coke oven corbel of claim 6, wherein the first side of the gun block portion includes at least one ledge portion, the second side of the gun block portion includes at least one ledge portion, the at least one ledge portion on the first side being positioned to receive a block thereon, and the at least one ledge portion on the second side being positioned to receive a block thereon.

10. A coke oven corbel, a gun block portion having a first end and a second end; the gun block portion has a longitudinal throughbore extending from the first end to the second end and has at least one generally vertical throughbore therein, the at least one generally vertical throughbore communicating with the longitudinal throughbore, the gun block portion further including at least one arrangement extending therefrom, the arrangement comprising: a base having a first side and a second side extending therefrom, the first side having a shoulder disposed thereon and the second side having a shoulder disposed thereon; a base having first and second sides extending therefrom, the base having a generally angular channel proximate the first end of the gun block portion, the generally angular channel having an opening within the group consisting of the first side of the base and the second side of the base; a first side surface and a second side surface extending from the gun block portion; a generally angular channel proximate the first end of the gun block portion and having an opening in the group consisting of the first side and the second side.

11. 11. The coke oven corbel of claim 10, wherein the gun block portion has an upper end, the upper end having at least one recess therein.

12. 11. The coke oven corbel of claim 10, wherein the vertical through hole has a recess proximate the first end of the gun block portion, and the vertical through hole has a lip extending therefrom and positioned proximate the second end of the gun block portion.

13. The coke oven corbel according to claim 12, wherein the recess of the vertical through-hole is positioned to receive a lip portion of the vertical through-hole of an adjacent corbel.

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