Brick prefabricated block, and manufacturing method thereof, arrangement structure, and arrangement method

Abstract

To provide a brick prefabricated block, a manufacturing method thereof, an arrangement structure, and an arrangement method, which can be economically constructed when forming a brick prefabricated block by stacking a plurality of checker bricks (brick stacks), without applying an adhesive to all contact surfaces between all of the checker bricks to bond the checker bricks together.SOLUTION: Among brick stacks 18 constituting a brick prefabricated block 2, contact surfaces between adjacent brick stacks 18 in one or both of a longitudinal direction of a slit 62 and a width direction of the slit 63 are bonded for some tiers including a lowermost tier in a vertical direction 61. The brick prefabricated block 2 is restrained by a plurality of bands 3 wound around the periphery thereof, wherein a part of the bands 3 is wound in contact with a top surface 21, a bottom surface 22, and an end surface 23 in the longitudinal direction of the slit of the brick prefabricated block 2, and another part of the bands 3 is wound in contact with the top surface 21, the bottom surface 22, and an end surface 24 in the width direction of the slit of the brick prefabricated block 2.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a prefabricated brick block formed by stacking a plurality of checker bricks, and to a manufacturing method, arrangement structure, and arrangement method thereof. [Background technology]

[0002] A coke oven consists of three main parts: a carbonization chamber where coal is carbonized; a combustion chamber where fuel is burned to supply heat to the carbonization chamber; and a heat storage chamber where heat is exchanged between the combustion exhaust gas from the combustion chamber and the fuel gas or combustion air.

[0003] The regenerator is filled with perforated bricks called checker bricks, and heat is exchanged between the combustion exhaust gas and the fuel gas or air through these checker bricks. In other words, the high-temperature exhaust gas flows from top to bottom through the regenerator for a certain period of time, heating the checker bricks, and conversely, the fuel gas or air flows from bottom to top, and the sensible heat of the heated checker bricks preheats the fuel gas or air.

[0004] A representative example of this checker brick will be described. FIG. 4(A) is a plan view of a checker brick 1, and FIG. 4(B) is a side view of the checker brick 1. As shown in FIG. 4(A), the checker brick 1 has multiple webs 12 provided within an outer frame 11, with slits 13 opening between the webs 12. Ridges 14 are provided perpendicular to the webs 12. When stacked one above the other, the checker bricks 1 have linear protrusions 16 at positions corresponding to the underside of the outer frame 11 in FIG. 4(A) so that a communication space 15 is formed between the underside of the slit 13 of the upper checker brick 1 and the checker brick 1 below it (FIG. 4(B)). The protrusions 16 are provided only at positions on the outer frame 11 that are aligned with the slit width direction 63 of the prefabricated block. In FIG. 4(A), the protrusions 16 are provided below the ends of the outer frame 11 in the slit longitudinal direction 62, but not below the ends of the outer frame 11 in the slit width direction 63. The communication spaces 15 allow adjacent slits 13 to communicate with each other, and the flow of gas is not impeded even if there is a misalignment between the upper and lower slits 13. Such checker bricks 1 are usually manufactured by pressure molding.

[0005] Conventionally, regenerators for coke ovens have been constructed by artisanal builders who lay checker bricks one by one. However, with the expected decline in the labor force, the construction period for furnace construction is currently being significantly extended.

[0006] One method for solving this problem is to use an adhesive to join multiple checker bricks 1 together (Patent Documents 1 to 3). That is, if multiple small checker bricks 1 are joined together in the horizontal and vertical directions with adhesive applied to the adhesive application areas of the checker bricks 1 to form a single large block, and these large blocks are then stacked one by one, the construction time required for furnace construction can be shortened.

[0007] The heat storage chamber is narrowly defined by walls called pillar walls and partition bricks. Because the space defined by the pillar walls and partition bricks is narrow, if an attempt is made to construct the heat storage chamber by placing checker bricks 1 inside the pillar walls using a jig that grips the large block from the side, the jig will interfere with the pillar walls and partition bricks, making it difficult to construct the heat storage chamber.

[0008] Patent Document 4 discloses a method for constructing a heat storage chamber, in which a large block is formed by bonding multiple checker bricks (heat storage chamber bricks) with adhesive. Multiple hanging rods are used to stack the large checker brick blocks. The hanging rods have a rod-shaped shaft that is linear in the vertical direction and a rod-shaped lower horizontal rod that is horizontally attached to the lower end of the shaft that supports the checker bricks. The diameters of the shaft and the lower horizontal rod of the hanging rod are thinner than the width of the slit (slot), the length of the lower horizontal rod of the hanging rod is longer than the width of the slit, and the height of the lower horizontal rod is shorter than the height of the communication space. When stacking the large blocks, cable ties may be attached to the sides of the large blocks. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Japanese Patent Application Publication No. 5-106979 [Patent Document 2] Japanese Patent Application Publication No. 6-179859 [Patent Document 3] Japanese Patent Publication No. 55-97412 [Patent Document 4] Japanese Patent Application Publication No. 2019-182939 Summary of the Invention [Problem to be solved by the invention]

[0010] In the inventions described in Patent Documents 1 to 3, multiple checker bricks are glued together to form a single large block, which is then stacked inside the heat storage chamber. However, when forming a large block, it is not economical to apply adhesive to all of the contact surfaces between the multiple checker bricks to bond them together. Hereinafter, the large block will be referred to as a prefabricated brick block.

[0011] An object of the present invention is to provide a prefabricated brick block, a manufacturing method for prefabricated brick blocks, an arrangement structure for prefabricated brick blocks, and an arrangement method for prefabricated brick blocks, which can be constructed economically when stacking a plurality of checker bricks to form a prefabricated brick block without applying adhesive to all of the contact surfaces between all of the checker bricks to bond them together. [Means for solving the problem]

[0012] That is, the gist of the present invention is as follows. [1] A brick prefabricated block made by stacking multiple checker bricks, The stacked individual checker bricks are called a brick masonry. Each of the stacked checker bricks has a plurality of slits penetrating through it, the penetrating direction of the slits is the vertical direction of the brick prefabricated block, the slits form an elongated shape in a plan view, the slit longitudinal direction of the slits in a plan view is called the slit longitudinal direction of the brick prefabricated block, and the direction perpendicular to both the slit longitudinal direction and the vertical direction is called the slit width direction of the brick prefabricated block, The brick masonry is arranged in two or more rows in the vertical direction of the brick prefabricated block, and in two or more rows in one or both of the slit longitudinal direction and the slit width direction, Among the brick masonry bodies, in some rows including the lowest row in the vertical direction, adjacent brick masonry bodies are bonded to each other in one or both of the slit longitudinal direction and the slit width direction, A brick prefabricated block characterized in that the brick prefabricated block is restrained by a plurality of bands wound around the brick prefabricated block, the bands are wound around the top and bottom surfaces of the brick prefabricated block, some of the bands are wound in contact with the two surfaces of the brick prefabricated block facing in the slit longitudinal direction, and other parts of the bands are wound around the two surfaces of the brick prefabricated block facing in the slit width direction. [2] A brick prefabricated block as described in [1], characterized in that some or all of the checker bricks have a shape in which the width of some of the slits (hereinafter referred to as "specific slits") is wider than the width of the other slits. [3] A brick prefabricated block as described in [2], characterized in that the width of the specific slit is at least 8 mm wider than the width of the other slits, and the slit width direction position of the bands that contact the upper surface, lower surface, and two slit longitudinal surfaces is at least 21 mm away from the slit width direction center position of the specific slit.

[0013] [4] A method for manufacturing a prefabricated brick block according to any one of [1] to [3], a guide having a first reference surface parallel to a surface of the prefabricated brick block facing the slit width direction and a second reference surface parallel to a surface of the prefabricated brick block facing the slit length direction; The brickwork is arranged so as to be pressed against the first reference surface and the second reference surface of the guide; Among the brick masonry bodies, for some rows including the lowest row in the vertical direction, adjacent brick masonry bodies are bonded to each other in one or both of the slit longitudinal direction and the slit width direction, A method for manufacturing a brick prefabricated block, characterized in that a plurality of the bands are wound around the brick prefabricated block, the bands are wound in contact with the upper and lower surfaces of the brick prefabricated block, some of the bands are wound in contact with the two surfaces of the brick prefabricated block facing in the slit longitudinal direction, and other parts of the bands are wound in contact with the two surfaces of the brick prefabricated block facing in the slit width direction.

[0014] [5] A brick prefabricated block arrangement structure in which the brick prefabricated block according to any one of [1] to [3] is arranged in a coke oven, The prefabricated brick block is arranged so that the slit longitudinal direction, slit width direction, and up-down direction are oriented in the furnace length direction, furnace battery length direction, and up-down direction of the coke oven, respectively; A prefabricated brick block arrangement structure characterized in that a plurality of spacers are arranged between the upper surface of a prefabricated brick block arranged below and the lower surface of another prefabricated brick block arranged above the prefabricated brick block.

[0015] [6] A construction method for placing the brick prefabricated block according to any one of [1] to [3] in a coke oven, The brick prefabricated block is arranged so that the slit longitudinal direction, slit width direction, and up-down direction are oriented in the furnace length direction, furnace battery length direction, and up-down direction of the coke oven, respectively; A method for arranging prefabricated brick blocks, characterized in that a plurality of spacers are placed between the upper surface of a prefabricated brick block to be placed below and the lower surface of another prefabricated brick block to be placed above the prefabricated brick block. [Effects of the Invention]

[0016] According to the present invention, when a plurality of checker bricks are stacked to form a prefabricated brick block, by bonding only some of the contact surfaces between all of the checker bricks rather than all of them, it is possible to provide a prefabricated brick block, a manufacturing method for a prefabricated brick block, an arrangement structure for prefabricated brick blocks, and an arrangement method for prefabricated brick blocks, which can be constructed economically. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a perspective view of a prefabricated brick block. [Figure 2] (A) is a plan view and (B) is a front view of a brick prefabricated block. [Figure 3] (A) is a plan view and (B) is a front view of a checker brick. [Figure 4] (A) is a plan view and (B) is a front view of a checker brick. [Figure 5] FIG. 1 is a perspective view showing the adhesive surface of a brick prefabricated block. [Figure 6] FIG. [Figure 7] 10A and 10B are plan views showing the state in which a lifting device is attached to a brick prefabricated block, where (A) shows the state in which the lifting device has been inserted, and (B) shows the state in which the lower horizontal bar part has been rotated. [Figure 8] 1A and 1B are diagrams showing a guide for forming a prefabricated brick block, in which (A) is a plan cross-sectional view taken along the line AA, and (B) is a side cross-sectional view taken along the line BB. [Figure 9] 1A and 1B are diagrams showing the arrangement of prefabricated brick blocks, in which (A) is a cross-sectional plan view taken along the line AA, and (B) is a front view. DETAILED DESCRIPTION OF THE INVENTION

[0018] The description will be made based on FIGS. 1 to 9.

[0019] The present invention relates to a prefabricated brick block 2 formed by stacking a plurality of checker bricks 1, as well as its manufacturing method, arrangement structure, and arrangement method. Each stacked checker brick 1 is called a brick masonry 18. The prefabricated brick block 2 refers to a block of checker bricks that have been stacked and fixed together by some means.

[0020] As described above, the checker brick 1 has a plurality of slits 13 penetrating the checker brick 1. When the checker bricks 1 are stacked in the regenerator chamber of a coke oven, the direction in which the slits 13 penetrate is the vertical direction 61 of the prefabricated brick block 2. The vertical direction 61 of the prefabricated brick block 2 and the vertical direction of the regenerator are the same direction. Therefore, the direction in which the slits 13 of the checker brick 1 penetrate is referred to as the vertical direction 61 of the prefabricated brick block 2. The slits 13 form an elongated shape in a plan view. In a plan view, the slit longitudinal direction of the slit 13 is referred to as the slit longitudinal direction 62 of the prefabricated brick block 2, and the direction perpendicular to both the slit longitudinal direction 62 and the vertical direction 61 is referred to as the slit width direction 63 of the prefabricated brick block.

[0021] In the prefabricated brick block 2 of the present invention, the brick masonry bodies 18 are arranged in two or more rows in the vertical direction 61 of the prefabricated brick block 2, and in two or more rows in either or both of the slit longitudinal direction 62 and the slit width direction 63. Fig. 1 shows an example in which checker bricks 1 (brick masonry bodies 18) are arranged in ten rows in the vertical direction 61 of the prefabricated brick block 2, two rows in the slit longitudinal direction 62, and one row in the slit width direction 63. The following description will be based on this example.

[0022] In the prefabricated brick block 2 of the present invention, in some rows of the brick masonry units 18, including the lowest row in the vertical direction 61, the contact surfaces between adjacent brick masonry units 18 in one or both of the slit longitudinal direction 62 and the slit width direction 63 of the prefabricated brick block 2 are bonded to form the bonding surface 17. In the example shown in Figure 5, the bonding surface 17 is indicated by dotted hatching. In the lowest row and the row above it (the second row from the bottom) in the vertical direction 61, the contact surfaces between adjacent brick masonry units in the slit longitudinal direction 62 are bonded to form the bonding surface 17, while other contact surfaces between the brick masonry units are not bonded. The bonding of the contact surfaces can be achieved using mortar or an adhesive. Since only the limited contact surfaces between the brick masonry units 18 constituting the prefabricated brick block 2 are bonded as the bonding surface 17, the prefabricated brick block 2 can be produced economically. The brickwork 18 may be bonded only to the lowest tier, but more preferably, the lowest tier and the upper tier are bonded together, which, combined with the effect of the bands 3 described below, prevents the brickwork 18 from shifting or coming apart when the prefabricated brick blocks 2 are moved and loaded into the regenerator. It is most preferable to bond the lowest tier and the upper tier.

[0023] Patent Document 4 also describes the use of cable ties on the sides of large blocks when stacking them. In the present invention, as described above, only the contact surfaces between adjacent brick masonry units 18 in either or both the slit longitudinal direction 62 and the slit width direction 63 are bonded for only some rows, including the lowest row, in the vertical direction 61 of the brick prefabricated block 2. Therefore, the cable ties described in Patent Document 4 cannot adequately prevent the brick masonry units 18 from shifting or being dismantled when the brick prefabricated block 2 is moved or loaded. To prevent the shifting of the brick masonry units 18, it is necessary to increase the frictional force of the horizontal joints (not bonded) between the brick masonry units 18. Increasing the frictional force of the horizontal joints requires the application of a vertical load between the brick masonry units 18. In the present invention, the brick prefabricated blocks 2 are restrained by bands 3 in a manner that allows the application of a vertical load between the brick masonry units 18.

[0024] That is, the prefabricated brick block 2 is restrained by a plurality of bands 3 wound around the prefabricated brick block 2, the bands 3 being wound in contact with the top surface 21 and bottom surface 22 of the prefabricated brick block 2, a portion of the bands 3 being wound in contact with the two surfaces of the prefabricated brick block 2 facing the slit longitudinal direction 62, and another portion of the bands 3 being wound in contact with the two surfaces of the prefabricated brick block 2 facing the slit width direction 63. Here, as shown in FIG. 5 , the two surfaces of the prefabricated brick block 2 facing the slit longitudinal direction 62 are called slit longitudinal end surfaces 23, and the two surfaces of the prefabricated brick block 2 facing the slit width direction 63 are called slit width direction end surfaces 24. The case where the bands 3 are wound in contact with the top surface 21, bottom surface 22, and two slit longitudinal end surfaces 23 is called "slit longitudinal winding 31." The case where the film is wound in contact with the upper surface 21, the lower surface 22, and the two slit width direction end surfaces 24 is called "slit width direction winding 32."

[0025] In the example shown in Figures 1 and 2, the brick prefabricated block 2 is restrained by eight bands 3, band A (3A) to band H (3H). Band A (3A) and band B (3B) are in contact with the upper surface 21 and lower surface 22 of the brick prefabricated block 2, and are wound around in contact with the slit longitudinal end surface 23, forming a slit longitudinal direction winding 31. Band C (3C) to band H (3H) are in contact with the upper surface 21 and lower surface 22 of the brick prefabricated block 2, and are wound around in contact with the slit width direction end surface 24, forming a slit width direction winding 32. That is, all of bands A (3A) to H (3H) are wound in contact with the upper surface 21 and the lower surface 22 of the brick prefabricated block 2, and some of the bands (band A (3A) and band B (3B)) are wound in contact with the two surfaces (slit longitudinal end surfaces 23) facing the slit longitudinal direction 62 of the brick prefabricated block 2, and other parts of the bands (bands C (3C) to band H (3H)) are wound in contact with the two surfaces (slit width direction end surfaces 24) facing the slit width direction 63 of the brick prefabricated block 2. By the slit longitudinal direction winding 31 of bands A (3A) and band B (3B), a load is applied in the up-down direction 61 of the brick prefabricated block 2, and a load is also applied in the slit longitudinal direction 62 of the brick prefabricated block 2, thereby sufficiently restraining the slit longitudinal direction 62 of the brick prefabricated block 2. A load is applied to the prefabricated brick block 2 in the up-down direction 61 by the winding 32 of the bands C (3C) to H (3H) in the slit width direction.

[0026] As shown in Figures 1 and 2, in an example where checker bricks 1 (brick masonry 18) are arranged in 10 rows in the vertical direction 61 of the brick prefabricated block 2, two rows in the slit longitudinal direction 62, and one row in the slit width direction 63, the results of friction force calculations have confirmed that sufficient restraining force can be obtained by restraining with a total of eight bands 3. PP bands with a width of 19 mm were used for the friction force calculations.

[0027] In the example shown in Figures 1 and 2, corner angles 33 are placed at the positions where the bands 3 contact the corners of the brick prefabricated blocks 2 in order to protect the brick prefabricated blocks 2. The corner angles 33 are made of cardboard, and once they are installed in the heat storage chamber and the heat storage operation begins, they burn up at high temperatures and disappear. The installation of the corner angles 33 is not essential.

[0028] The bands 3 thermally expand due to temperature changes during storage and transportation of the brick prefabricated blocks 2. Therefore, a material that can restrain the brick prefabricated blocks 2 even when thermally expanded is used for the bands 3. It is desirable to use a polypropylene material for the bands 3, which has a wide elastic deformation range and is stretchable.

[0029] As described above, the underside of the checker brick 1 normally has a linear convex portion 16 at a position corresponding to the underside directly below the outer frame 11 (see FIG. 4(B)). For the band 3 (slit width direction winding 32) wound so as to contact the slit width direction end face 24 of the prefabricated brick block 2, if the band 3 is wound so as to contact the part of the lowest checker brick other than the convex portion 16 (the part of the communicating space 15), this is preferable because after the prefabricated brick block 2 is installed in the heat regenerator, the band 3 does not come into contact with the structure below the prefabricated brick block 2, allowing the band 3 to be removed after installation. For the band (slit length direction winding 31) wound so as to contact the slit length direction end face 23 of the prefabricated brick block 2, the band can be removed after installation if a spacer, described below, is installed.

[0030] As for the checker bricks 1 to be installed in the regenerator of a coke oven, as in the present invention, a plurality of checker bricks 1 are stacked to form a prefabricated brick block 2, which is then installed in the regenerator. The prefabricated brick block 2 may be formed in a location adjacent to the coke oven. Alternatively, the prefabricated brick block may be formed in a location remote from the coke oven. When the prefabricated brick block 2 is formed in a remote location, it is transported from the remote location to the location of the coke oven and installed in the regenerator from a temporary storage area near the coke oven. In either case, the formed prefabricated brick block 2 must be transported.

[0031] As mentioned above, the regenerator chamber is narrowly defined by the pillar walls and partition bricks. Because the space defined by the pillar walls and partition bricks is narrow, if a prefabricated brick block is gripped from the side with a jig and placed inside the pillar wall, the gripping jig will interfere with the pillar walls and partition bricks, making it difficult to construct the regenerator chamber. In this invention, similar to the invention described in Patent Document 4, it is preferable to transport the prefabricated brick block 2 using a lifting rod 4 shown in Figure 6. The lifting rod 4 has a vertically linear rod-shaped shaft 41 and a rod-shaped lower horizontal rod 42 attached horizontally to the lower end of the shaft 41, which supports the checker brick 1. The lifting rod 4 is lowered through the slit 13 in the checker brick 1 to the bottom end of the prefabricated brick block 2 (Figure 7(A)). The length of the lower horizontal bar portion 42 of the hanging rod 4 is longer than the width of the slit 13 (Fig. 7(B)), and the height of the lower horizontal bar portion 42 is shorter than the height of the convex portion 16. Since the hanging rod 4 is lowered to the lower end of the brick prefabricated block 2 through the slit 13 of the checker brick 1, it is necessary that the thickness of the shaft portion 41 and the lower horizontal bar portion 42 of the hanging rod 4 be thinner than the width of the slit 13. In the example of Fig. 6, an upper horizontal bar portion 43 is formed at the upper end of the hanging rod 4.

[0032] In order to maximize the heat exchange efficiency of the checker bricks 1, it is effective to increase the number of slits 13. Therefore, the width of the slits 13 is narrowed as much as possible, resulting in an increased number of slits 13 arranged in the slit width direction 63 of the checker bricks 1. When lifting the prefabricated brick block 2, a lifting rod 4 is inserted through the slits 13 of the checker bricks 1 stacked in multiple layers in the vertical direction 61. If misalignment occurs between the vertically stacked checker bricks 1 in the slit width direction 63, the space for inserting the lifting rod 4 will be narrowed by the amount of misalignment. If the diameters of the shaft 41 and lower horizontal rod 42 of the lifting rod 4 are made thinner than the width of the slits 13 of the existing checker bricks 1 and the narrowing width that would be expected if they were misaligned, the maximum lifting load of the lifting rod 4 would be reduced, which may make it difficult to lift the prefabricated brick block 2.

[0033] In the present invention, preferably, some or all of the checker bricks 1 have a shape in which the width of some of the slits 13 (specific slits 19) is wider than the width of the other slits 13, as shown in FIG. 3 . The slit 13 through which the lifting rod 4 passes is designated as the specific slit 19, and is the slit into which the lifting rod 4 is inserted. Because the specific slit 19 is wider than the other slits 13, the shaft 41 and lower horizontal rod 42 of the lifting rod 4 can be made thicker, increasing the maximum lifting load of the lifting rod 4 and making it easier to lift the prefabricated brick block 2. The width of the specific slit 19 is preferably at least 8 mm wider than the width of the other slits 13. Typically, the width of the slit 13 is approximately 11 mm. If the width of the specific slit 19 is at least 8 mm wider than the width of the other slits 13, the width of the specific slit 19 can be approximately 19 mm. Even if there is a deviation of about 10 mm in the slit width direction 63 between the checker bricks in the vertical direction 61, the thickness of the shaft portion 41 and the lower end horizontal rod portion 42 of the hanging rod 4 can be increased to about 9 mm, and the possible hanging load of the hanging rod 4 can be sufficiently increased.

[0034] When using the hanging rod 4, the direction of the lower horizontal bar portion 42 of the hanging rod 4 is aligned with the slit longitudinal direction 62 of the checker brick 1 and inserted into the specific slit 19 (Fig. 7(A)), the hanging rod 4 is inserted until the lower horizontal bar portion reaches the bottom end of the brick prefabricated block, the inserted hanging rod is rotated about a vertical axis so that the direction of the lower horizontal bar portion 42 is aligned with the slit width direction 63 of the checker brick 1 (Fig. 7(B)), the lower horizontal bar portion 42 supports the web 12 of the checker brick 1, the brick prefabricated block 2 supported by the web 12 is lifted up, moved to a predetermined location and placed there.

[0035] In the present invention, the bands 3 are wound around the prefabricated brick block 2. The bands 3 are wound in contact with the upper surface 21 and the lower surface 22 of the prefabricated brick block 2. Therefore, if the lower horizontal bar 42 on the lower surface 22 has been rotated so that it faces in the slit width direction 63, and comes into contact with the bands 3 wound around the lower surface 22, the bands 3 will be pinched between the lower horizontal bar 42 and the lower surface 22 when the prefabricated brick block 2 is lifted, and the bands 3 will be damaged.

[0036] In the present invention, as shown in Fig. 7, the position in the slit width direction of the bands (slit longitudinal direction windings 31) that contact the upper surface 21, the lower surface 22, and the two slit longitudinal surfaces (slit longitudinal direction end surfaces 23) of the band 3 is preferably positioned 21 mm or more away from the slit width direction center position of the specific slit 19. In other words, d ≥ 21 mm in Fig. 7(B). In this case, by setting the length L of the lower end horizontal bar portion 42 of the hanging rod 4 to 41 mm or less, the lower end horizontal bar portion 42 that has rotated on the lower surface 22 and faces the slit width direction 63 will not damage the band 3 wound around the lower surface 22.

[0037] Next, a method for manufacturing the prefabricated brick block 2 will be described.

[0038] As described above, it is necessary to insert the lifting rod 4 through the slits 13 of the checker bricks 1 (brick masonry bodies 18) stacked in the vertical direction 61 in the brick prefabricated block 2. To achieve this, as described above, it is important to stack the brick masonry bodies 18 in the vertical direction 61 so as to minimize horizontal misalignment between them. In the manufacturing method of the brick prefabricated block 2 of the present invention, preferably, as shown in FIG. 8, a guide 5 for stacking is prepared, which has a first reference surface 51 parallel to the surface facing the slit width direction 63 of the brick prefabricated block 2 (slit width direction end surface 24). More preferably, a guide 5 is prepared which has a second reference surface 52 parallel to the surface facing the slit longitudinal direction 62 of the brick prefabricated block 2 (slit longitudinal direction end surface 23). Since the surface of the prefabricated brick block facing the slit width direction (slit width direction end surface 24) and the surface facing the slit longitudinal direction (slit longitudinal direction end surface 23) are both vertical, it is preferable that the first reference surface 51 and the second reference surface 52, which are parallel to these surfaces, are also vertical. A guide 5 having such first reference surface 51 and second reference surface 52 is prepared, and the checker bricks 1 are stacked using this guide 5 to form a brickwork 18, thereby producing a prefabricated brick block 2. The brickwork 18 is positioned so that it is pressed against the first reference surface 31 and the second reference surface 32 of the guide 5. By positioning the brickwork 18 so that it is pressed against the first reference surface 51, it is possible to minimize the amount of misalignment between the brickworks 18 in the slit width direction in the up-down direction 61. Furthermore, by arranging the brickwork 18 so as to press it against the second reference surface 52, the amount of deviation in the slit longitudinal direction 62 between the brickwork 18 in the vertical direction 61 can be minimized.

[0039] As shown in Figure 5, for some rows of brickwork 18, including the bottom row, adjacent brickwork 18 are bonded together in either or both of the slit longitudinal direction 62 and the slit width direction 63 to form bonding surfaces 17. When bonding, adhesive or mortar is applied to the contact surfaces before the two surfaces are brought into contact. It is desirable that the adhesive or mortar has an adhesive strength equal to or greater than the bending strength of the checker bricks.

[0040] After the laying of the brick masonry 18 of the prefabricated brick blocks 2 is completed, a plurality of bands 3 are wound around the prefabricated brick blocks 2. The bands 3 are wound in contact with the upper surface 21 and the lower surface 22 of the prefabricated brick blocks 2. Some of the bands are wound in contact with the two surfaces of the prefabricated brick blocks 2 that face the slit longitudinal direction 62 (slit longitudinal end surfaces 23) (slit longitudinal direction winding 31), and other parts of the bands 3 are wound in contact with the two surfaces of the prefabricated brick blocks 2 that face the slit width direction 63 (slit width direction end surfaces 24) (slit width direction winding 32).

[0041] The arrangement structure and arrangement method of the prefabricated brick blocks placed inside the coke oven will be described.

[0042] When placing the brick prefabricated block in the coke oven, the brick prefabricated block 2 is placed so that the slit longitudinal direction 62, slit width direction 63, and up-down direction 61 of the block face the oven length direction 64, oven batter length direction 65, and up-down direction 61 of the coke oven, respectively (see Figure 9).

[0043] As described above, in the process of stacking brick masonry bodies 18 to form a prefabricated brick block 2, the guide 5 having the first and second reference surfaces 51 and 52 can be used to minimize horizontal misalignment between the brick masonry bodies 18 in the vertical direction 61. The formed prefabricated brick block 2 is then placed in the regenerator of a coke oven. For two adjacent prefabricated brick blocks (see FIG. 9 ) in the vertical direction 61, it is also necessary to minimize misalignment between the lower prefabricated brick block (also referred to as the “lower block 25”) and the upper prefabricated brick block (also referred to as the “upper block 26”). If the positions of the lower block 25 and the upper block 26 are misaligned in the slit width direction 63 (furnace bunk length direction 65), the flow of gas from the slit at the upper end of the lower block 25 to the slit at the lower end of the upper block 26 is obstructed, resulting in increased pressure loss of the flowing gas. By providing the protrusion 16 on the underside of the checker brick at the lower end of the upper block 26, pressure loss can be kept to a minimum even if the above-mentioned misalignment occurs. However, depending on the size of the misalignment, the pressure loss may become significant.

[0044] In the present invention, as shown in FIG. 9, preferably, multiple spacers 7 are placed between the upper surface 21 of a lower brick prefabricated block (lower block 25) and the lower surface 22 of another brick prefabricated block (upper block 26) placed above the lower brick prefabricated block. As a result, multiple spacers 7 are placed between the upper surface 21 of the lower block 25 and the lower surface 22 of the upper block 26. In the example shown in FIG. 9(A), nine spacers 7 each having a rectangular shape in a plan view are placed. By ensuring that the spacers 7 have a height H in the height direction when placed in the furnace, a rectifying layer 71 is formed when gas passes from the slits in the lower block 25 to the slits in the upper block 26, thereby reducing gas pressure loss. The height H of the spacers 7 in the height direction is preferably approximately 20 to 40 mm. To reduce gas pressure loss, a height approximately twice the slit width is preferred. To prevent the spacers from tipping over when the upper block 26 is installed, the slit height is preferably at most approximately 40 mm. The width of the spacer 7 in the slit width direction is preferably as wide as possible so that it can withstand compressive stress, since it bears the weight of the upper block 26. However, it is not necessary for the width to exceed the protrusion 16 on the lower surface of the checker brick at the lower end of the upper block 26. [Explanation of symbols]

[0045] 1 checker brick 11 Outer Frame 12 Web 13 Slit 14 Ridge 15 Communication space 16 Convex part 17 Adhesive surface 18 Brick masonry 19 Specific slit 2. Prefabricated brick blocks 21 Top side 22 Bottom side 23 Slit longitudinal end face 24 Slit width direction end face 25 Lower Block 26 Upper Block 3 bands 31 Slit longitudinal winding 32 Slit width direction winding 33 Corner Angle 4... Lifting rod 41...Shaft 42…Lower end horizontal bar part 43...Top horizontal bar part 5 Guide 51 1st reference plane 52 2nd reference plane 61 Up and down direction 62 Slit longitudinal direction 63 Slit width direction 64 Furnace length direction 65 Furnace Leader Direction 7 spacers 71 Rectifier layer

Claims

1. A brick prefabricated block formed by stacking a plurality of checker bricks, The stacked individual checker bricks are called a brick masonry. Each of the stacked checker bricks has a plurality of slits penetrating through it, the penetrating direction of the slits is the vertical direction of the brick prefabricated block, the slits form an elongated shape in a plan view, the slit longitudinal direction of the slits in a plan view is called the slit longitudinal direction of the brick prefabricated block, and the direction perpendicular to both the slit longitudinal direction and the vertical direction is called the slit width direction of the brick prefabricated block, The brick masonry is arranged in two or more rows in the vertical direction of the brick prefabricated block, and in two or more rows in one or both of the slit longitudinal direction and the slit width direction, Among the brick masonry bodies, in some rows including the lowest row in the vertical direction, adjacent brick masonry bodies are bonded to each other in one or both of the slit longitudinal direction and the slit width direction, A brick prefabricated block characterized in that the brick prefabricated block is restrained by a plurality of bands wound around the brick prefabricated block, the bands are wound around the top and bottom surfaces of the brick prefabricated block, a portion of the bands are wound around the two surfaces of the brick prefabricated block facing in the slit longitudinal direction, and another portion of the bands are wound in contact with the two surfaces of the brick prefabricated block facing in the slit width direction.

2. The brick prefabricated block according to claim 1, characterized in that some or all of the checker bricks have slits (hereinafter referred to as "specific slits") wider than the other slits.

3. A brick prefabricated block as described in claim 2, characterized in that the width of the specific slit is 8 mm or more wider than the width of the other slits, and the slit width direction position of the bands that contact the upper surface, lower surface, and two slit longitudinal surfaces is positioned 21 mm or more away from the slit width direction center position of the specific slit.

4. A method for manufacturing a prefabricated brick block according to any one of claims 1 to 3, a guide having a first reference surface parallel to a surface of the prefabricated brick block facing the slit width direction and a second reference surface parallel to a surface of the prefabricated brick block facing the slit length direction; The brickwork is arranged so as to be pressed against the first and second reference surfaces of the guide; Among the brick masonry bodies, for some rows including the lowest row in the vertical direction, adjacent brick masonry bodies are bonded to each other in one or both of the slit longitudinal direction and the slit width direction, A method for manufacturing a brick prefabricated block, characterized in that a plurality of the bands are wound around the brick prefabricated block, the bands are wound in contact with the upper and lower surfaces of the brick prefabricated block, some of the bands are wound in contact with two surfaces of the brick prefabricated block facing in the slit longitudinal direction, and other parts of the bands are wound in contact with two surfaces of the brick prefabricated block facing in the slit width direction.

5. A brick prefabricated block arrangement structure in which the brick prefabricated block according to any one of claims 1 to 3 is arranged in a coke oven, The prefabricated brick block is arranged so that the slit longitudinal direction, slit width direction, and up-down direction are oriented in the furnace length direction, furnace battery length direction, and up-down direction of the coke oven, respectively; A prefabricated brick block arrangement structure characterized in that a plurality of spacers are arranged between the upper surface of a prefabricated brick block arranged below and the lower surface of another prefabricated brick block arranged above the prefabricated brick block.

6. A construction method for placing the prefabricated brick block according to any one of claims 1 to 3 in a coke oven, The brick prefabricated block is arranged so that the slit longitudinal direction, slit width direction, and up-down direction are oriented in the furnace length direction, furnace battery length direction, and up-down direction of the coke oven, respectively; A method for arranging prefabricated brick blocks, comprising the steps of: placing a plurality of spacers between the upper surface of a prefabricated brick block to be placed below and the lower surface of another prefabricated brick block to be placed above the prefabricated brick block;

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