Stave protection system

Abstract

A stave protection system for a metallurgical furnace includes a stave (100) including upper and lower ribs (114), the upper and lower ribs (114) protruding forward from a front face (102) of the stave (100) and being spaced apart from each other so as to define a transverse groove portion (112), a stave (100); at least one insert (200) being partially positioned in the groove portion (112) and fixedly engaged with the upper and lower ribs (114) so as to protrude forward of the upper and lower ribs (114), at least one insert (200); and a brace (300; 400; 500) being positioned between a front surface (114a) of the lower rib (114) and an opposing rear surface (212) of the insert (200), the brace (300; 400) opposing a force (FD, FL, FR) applied to the insert (200) and resisting displacement of the opposing rear surface (212) of the insert (200) toward the front surface (114a) of the lower rib (114) during use.

Description

Technical Field

[0001] The present invention relates to a stave protection system for metallurgical furnaces, such as blast furnaces.

Background Art

[0002] Conventional blast furnaces include several sections and components, including a stack, bosh, tuyeres, hearth, and taphole. The inner shell of the blast furnace can be protected by water-cooled cooling plates (referred to as staves), which protect the shell from overheating during the reduction process taking place in the furnace. Modern staves are typically constructed from copper or copper alloys, although other materials, such as steel or cast iron, can also be used.

[0003] Staves can be susceptible to abrasive wear from the raw materials as the solid raw materials charged into the furnace descend through the furnace. Wear can occur due to the abrasion caused by the descending charged material and the outward pressure exerted on the stave surface by the material, either locally at one or more locations or across the entire surface of the stave. In particular, coke is highly abrasive. In some situations, the severity of the wear results in the need to replace the staves before the planned service life of the staves has ended. This is costly due to furnace downtime.

[0004] Therefore, efforts have been made to design staves with an extended service life.

[0005] It is known that wear of the stave is reduced by forming a frozen accretion layer on the front face of the stave during operation. For this purpose, the stave has a machined front face (or hot face) including ribs and grooves for retaining deposits on the stave. A portion of an exemplary copper stave of this type is shown in FIG. 1.

[0006] An improvement of this concept is the addition of a front face protection material or cladding material, which is harder than the copper-based material, but which still allows a protective accretion layer to form by freezing on the face. For example, the applicant's published patent document 1 describes a stave protection system including inserts attached to the face of the stave. The inserts are shaped to distribute a filling material between the inserts on the front face of the stave and / or to capture a filling material between the inserts, thereby forming a frozen accretion layer on the front face of the stave during operation.

[0007] Also, the applicant's published patent document 2 describes an insert or "adherend" for attachment to the face of the stave. FIG. 2 herein, taken from this publication, shows a multi-piece insert configured to be conveniently installed into the grooves (formed between the ribs of the stave) from the front of the stave without the need for access to the edge of the stave to slide the insert laterally into the grooves.

[0008] The insert described by Patent Document 2 is effective in extending the service life of the staple, but the Applicant has found that the attachment between the insert and the groove / rib of the staple may ultimately become weak over time, and the insert may come off the staple. One reason for this is that when the furnace temperature is increased, the copper alloy material of the staple tends to expand more than the steel material of the insert, causing the insert to lose its frictional grip on the surface of the staple. Therefore, the insert may loosen in the groove, and the insert may be able to move relative to the rib of the staple under the pressure exerted on the insert by the filling material. The extended and repeated movement of the harder steel insert tends to wear away the softer copper alloy of the rib, causing the insert to loosen further and ultimately fall completely out of the groove. Moreover, the Applicant has observed that this loosening of the insert typically occurs at an earlier stage when the insert is fitted to a staple with partially worn ribs than when it is fitted to a new (or readjusted) staple with unworn ribs.

Prior Art Documents

Patent Documents

[0009]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0010] The present invention aims to at least somewhat alleviate the problems of the prior art.

Means for Solving the Problems

[0011] According to one aspect of the present invention, there is provided a stave protection system for a metallurgical furnace, comprising: a stave including upper and lower ribs, the upper and lower ribs protruding forward from a front face of the stave and being spaced apart from each other to define a transverse groove; at least one insert partially positioned within the groove and fixedly engaged with the upper and lower ribs so as to protrude forward of the upper and lower ribs; and a brace positioned between a front surface of the lower rib and an opposing rear surface of the insert, the brace being configured to counteract a force applied to the insert and resist displacement of the rear surface of the insert toward the front surface of the lower rib during use.

[0012] As used herein, "charged material" refers to one or both of (i) a material containing iron in a blast furnace (e.g., iron ore or iron ore pellets) and (ii) a blast furnace slag (i.e., a slag formed when iron ore or iron pellets, coke, and flux (e.g., limestone or dolomite) are melted together in a blast furnace and then solidified).

[0013] As will be described in more detail later herein, during use of the furnace, the insert may be subjected to downward (vertical) and lateral (horizontal) forces (or combinations thereof) exerted on the insert by the charged material. The charged material has an abrasive effect on the lower rib, while the force applied to the insert by the charged material tends to move (e.g., pivot) the insert and displace the insert toward the lower rib. Over time, the effects of wear and movement of the insert cause wear to the lower rib, which can ultimately cause the insert to loosen and disengage from the stave.

[0014] The brace of the claimed invention effectively extends the lower rib forward to the opposing rear surface of the insert. In this regard, the brace "repairs" the partially worn lower rib. Thus, the brace is arranged to counteract (i.e., oppose) the force applied to the insert during use, thereby resisting the displacement of the rear surface of the insert towards the front surface of the lower rib. Accordingly, the brace serves to reinforce or strengthen the lower rib and stabilize the lower rib in order to prevent (or at least limit) the movement of the insert due to the force exerted on the insert. Thus, the insert is held in the groove on the face of the stave. Due to the retention of the protective insert, the wear rate of the rib is reduced and the service life of the stave is extended.

[0015] Moreover, the brace is an inexpensive "retrofit" item that can be conveniently produced in a variety of sizes to fit any given size gap between the front surface of the lower rib and the opposing rear surface of the insert (the size of the gap depending on the degree of wear of the stave rib in any given case). Moreover, the installation of the stave protection system and its brace is simple and time - efficient, thus minimizing the furnace downtime and thereby minimizing costs.

[0016] Accordingly, the claimed invention provides an effective and efficient solution to the problem of how to extend the service life of a partially worn stave.

[0017] The brace can extend completely between the front surface of the lower rib and the opposing rear surface of the insert.

[0018] The brace can extend partially between the front surface of the lower rib and the opposing rear surface of the insert.

[0019] The brace can be further positioned between the front surface of the upper rib and the opposing rear surface of the insert, and in use, the brace resists the force applied to the insert and resists the displacement of the rear surface of the insert towards the front surface of the upper rib.

[0020] The brace can include a plurality of discrete brace elements arranged opposite each other.

[0021] The brace can include a single brace element having a unitary structure.

[0022] The insert can include a wedge-shaped attachment part at least partially received between the opposing inclined wall parts of the upper and lower ribs so as to integrally form a joint, and a protruding part protruding in front of the upper and lower ribs and including the rear surface of the insert, and the attachment part and the brace are configured to engage with each other and position the brace between the front surface of the lower rib and the opposing rear surface of the insert.

[0023] The brace can be received in a slot provided in the attachment part.

[0024] The upper part of the brace can be configured to engage with the attachment part so as to prevent the brace from falling out of the slot.

[0025] The rear surface of the insert can include a generally flat formation that extends into the slot, the brace can include a planar sheet part and parallel ribs, the parallel ribs extend perpendicularly from the planar sheet part and form channels between the parallel ribs, the brace is selectively reversible between a first orientation and a second orientation, in the first orientation, the planar sheet part faces the flat formation and the parallel ribs face the front surface of the lower rib, in the second orientation, the planar sheet part faces the front surface of the lower rib and the flat formation is received in the channel between the parallel ribs, and the brace thereby spans a greater distance between the front surface of the lower rib and the flat formation when in the first orientation than when in the second orientation.

[0026] The lateral width of the attachment part can be smaller than the lateral width of the protruding part, the brace can include first and second upright members, the first and second upright members are laterally spaced apart from each other and joined by a cross member, the cross member extends laterally along the upper surface of the attachment part and is thereby supported, each of the first and second upright members depends on a respective end of the cross member and is adapted to extend along a respective side of the attachment part.

[0027] The lateral spacing between the upright members can be substantially equal to the lateral width of the attachment part, and the inner edge of each of the upright members contacts the outer edge of the respective side of the attachment part, thereby suppressing lateral movement of the brace relative to the insert.

[0028] The stay protection system can include a plurality of inserts and a plurality of braces each positioned between the front surface of the lower rib and a respective opposing rear surface of the plurality of inserts.

[0029] According to another aspect of the present invention, there is provided a kit of parts for a stabbing protection system as described above herein, the kit including at least one of said inserts for said engagement with the upper and lower ribs of the stabbing member, and at least one of said braces for disposition between a front surface of the lower rib of the stabbing member and an opposing rear surface of at least one of said inserts.

[0030] According to another aspect of the present invention, there is provided a method of installing a stabbing protection system as described above herein, the method including the steps of fixedly attaching an insert to the upper and lower ribs of the stabbing member, selecting a brace of appropriate thickness according to the distance between a front surface of the lower rib and an opposing rear surface of the insert, and disposing the brace between a front surface of the lower rib and an opposing rear surface of the insert.

[0031] The step of disposing the brace between a front surface of the lower rib and an opposing rear surface of the insert can include the step of positioning the brace so as to extend completely between a front surface of the lower rib and an opposing rear surface of the insert.

[0032] The step of disposing the brace between a front surface of the lower rib and an opposing rear surface of the insert can include the step of positioning the brace so as to extend partially between a front surface of the lower rib and an opposing rear surface of the insert.

[0033] The method can further include the step of disposing a brace between a front surface of the upper rib and an opposing rear surface of the insert.

[0034] Examples will now be described with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0035]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6a

Figure 6b

Figure 7a

Figure 7b

Figure 7c

Figure 7d

Figure 8

DETAILED DESCRIPTION OF THE INVENTION

[0036] Referring to FIG. 3, the rectangular cooling plate or stave 100 includes a front face (or hot face) 102, a rear face 104, and edges 106a - d (the bottom edge 106d is not shown in FIG. 3). The stave 100 is intended to be one of a plurality of similar staves for use in a blast furnace.

[0037] In this example, the stave 100 has a width of approximately 1.0 m (in the X - direction as meant in FIG. 3), a height of approximately 1.5 m (in the Y - direction as meant in FIG. 3), and a maximum thickness or depth of approximately 120 mm (in the Z - direction as meant in FIG. 3). It is understood that the X, Y, Z notations for width, height, and depth are for reference convenience only and are not limiting with respect to the claimed invention.

[0038] The interior of the stave 100 includes water - cooling passages 110. The body of the stave 100 is generally solid on other sides.

[0039] In this example, the stave 100 is constructed from a copper alloy. Alternative materials include, but are not limited to, copper, steel, and cast iron.

[0040] The front of the stave 100 includes a plurality of similar grooves 112, which are arranged in rows and separated from each other by protruding ribs 114. In this example, there are 12 grooves 112 and 13 ribs 114 (only some of which can be seen in FIG. 3, which shows only a part of the stave 100). Each groove 112 extends across the entire width of the stave 100 and has open ends at each of the side edges 106a, 106c of the stave 100. Each of the grooves 112 has a major axis L, which extends between the ends of the groove (in the X - direction as meant in FIG. 3).

[0041] In this example, the grooves 112 are formed by machining. Alternatively, the grooves 112 can be formed by casting.

[0042] Each one of the groove portions 112 includes a flat base or floor 112a. Each one of the groove portions 112 further includes a pair of opposing wall portions 112b. Each one of the opposing wall portions 112b is a surface of one of two adjacent ribs 114 that define the groove portion 112. Each one of the ribs 114 includes a rib surface 114a. The rib surface 114a is parallel to the floor 112a of the groove portion 112 (when at least the rib surface 114a is not worn). Thus, the front face 102 of the staple 100 can be regarded as including two parts (i.e., the foremost part that constitutes the rib surface 114a of the protruding rib 114, and the recessed part that constitutes the flat floor 112a of the groove portion 112).

[0043] Each one of the two opposing wall portions 112b of each one of the groove portions 112 is inclined so as to provide each one of the groove portions 112 with a converging taper from the floor 112a of the groove portion 112 to the respective surface 114a of the rib 114 that defines the groove portion 112. Thus, each one of the groove portions 112 presents a wedge-shaped profile (when viewed from the side edge portions 106a, 106c of the staple 100), with the thickest section of the wedge positioned at the floor 112a of the groove portion 112 and the thinnest section of the wedge positioned at the surface 114a of the rib 114.

[0044] Referring now to FIG. 4, a plurality of inserts 200 are attached to the front face 102 of the staple 100. Each one of the inserts 200 is generally of the type described in Patent Document 2, which is hereby incorporated by reference in its entirety. However, it should be understood that the claimed invention is not limited to this type of insert. The inserts 200 are arranged on the front face 102 of the staple 100 as described in Patent Document 1, which is hereby incorporated by reference in its entirety, so as to distribute a filling material between the inserts 200 across the front face of the staple 100 and / or to trap a filling material between the inserts 200.

[0045] Referring now to FIG. 5, an exemplary one of the inserts 200 of FIG. 4 is shown attached to the front face 102 of the stave 100 (shown from the side). Exemplary upper and lower ribs 114 of the stave 100 are in a partially worn condition (worn down in the Z direction from right to left in the sense of FIG. 5), such that the ribs 114 extend vertically (in the Z direction from left to right in the sense of FIG. 5) a lesser distance from the flat floor 112a of the groove 112 than would be the case for the ribs of a new stave in an unworn condition. It will be appreciated that the front face 114a of the upper or lower rib 114 may be worn along the entire length of the rib 114 (in the X direction in the sense of FIG. 5) or only a portion thereof.

[0046] In this example, the insert 200 is constructed from steel. Alternative materials include, but are not limited to, copper, copper alloys, and cast iron. The insert 200 can include a wear-resistant refractory material. The wear-resistant refractory material can include silicon carbide or alumina. The insert 200 itself is suitable for installation onto a new stave or a stave in a partially worn condition, as will be described below herein.

[0047] The insert 200 is formed by upper and lower half pieces which are pivotally arranged about pins 202 positioned within grooves formed by the half pieces. Each of the upper and lower half pieces includes a rear part 204 which includes a surface for engagement with the respective upper or lower wall portion 112b of the groove 112, the surface being configured to complement the inclination angle of the wall portion 112b. Thus, the rear parts 204 of the upper and lower half pieces together form the wedge-shaped attachment part 206 of the insert 200. In this example, the engagement surface includes serrations provided thereon.

[0048] Each of the upper and lower half pieces further includes a front part 208, which protrudes forward (in the Z direction from left to right in the sense of FIG. 5), and is adapted to receive and distribute the flowing charge material when the furnace is in use. Thus, the front parts 208 of the upper and lower half pieces together form the protruding part 210 of the insert 200.

[0049] The insert 200 further includes clamp nuts and bolts (not visible in FIG. 5), which pass through the front part 208 (in the Y direction from top to bottom in the sense of FIG. 5) and are configured to adjust the half pieces.

[0050] The installation of the insert 200 on the front face 102 of the stave 100 (as shown in FIG. 5) will be described here.

[0051] First, the nuts and bolts are in a loose condition, and the upper and lower half pieces are rotatable back and forth about the pin 202 relative to each other. The insert 200 is inserted into the stave 100 just in front of the upper and lower ribs 114. The front part 208 is grasped by hand and rotated in the opposite direction to move the rear parts 204 closer to each other (thus, the upper rear part 204 is rotated counterclockwise in the sense of FIG. 5, and the lower rear part 204 is rotated clockwise). Then, the insert 200 is moved (in the Z direction from right to left in the sense of FIG. 5) towards the flat floor 112a of the groove 112. When the ends of the rear parts 204 reach the flat floor 112a, the front part 208 is rotated back again and moved to move the rear parts 204 away from each other until each of the engaging surfaces of the rear parts 204 contacts the respective wall part 112b of the groove 112 (thus, the upper rear part 204 is rotated clockwise in the sense of FIG. 5, and the lower rear part 204 is rotated counterclockwise).

[0052] Next, the nut and bolt are tightened and are further configured to drive the rear parts 204 away from each other, thereby applying an outward clamping force to the wall portion 112b of the groove portion 112. The serrations on the engagement surface of the steel rear parts 204 penetrate or "bite" into the copper alloy material of the wall portion 112b and are configured to provide a non-slip contact therewith. It will be appreciated that the rear parts 204 together form a wedge that locks into the groove portion 112 in the form of a butt joint. Thus, the insert 200 is rigidly attached or fixed to the stave 100. The nut and bolt can be tack welded to prevent them from loosening during service in an operating furnace.

[0053] It will be recalled that the upper and lower ribs 114 of the stave 100 are in a partially worn condition. Thus, as can be seen in FIG. 5, a gap G exists between the front face 114a of the rib 114 and the rear surface 212 of the protruding part 210 of the attached insert 200.

[0054] As described above herein, during operation of the furnace, the charge material flows downwardly (generally in the Y direction from the top to the bottom in the sense of FIG. 5) over the stave 100 under gravity and contacts the protruding part 210 of the insert 200. Thus, the charge material applies a downward force FD to the insert 200 (as indicated by the arrow in FIG. 5). Moreover, the charge material has a tendency to apply a lateral force FL (or a force having a lateral component) in the direction of the stave 100 to the protruding part 210 (as indicated by the arrow in FIG. 5). The lateral force FL can be caused by the moving charge material and / or by the static load applied to the insert 200 by the charge material accumulated in front of the insert 200, resulting in a dynamic impact on the insert 200.

[0055] During use of the furnace, the insert 200 may be subjected to either the downward force FD and / or the lateral force FL alone, or to both of these forces in combination. In practice, the forces are typically applied in combination, and the resultant force FR (as indicated by the arrow in FIG. 5) tends to move the insert 200, for example, by rotation or pivoting T of the insert 200 (as indicated by the arrow in FIG. 5) about the pivot point P where the wall portion 112b intersects the edge of the lower rib 114 on the front face 114a, causing the rear surface 212 of the protruding part 210 to be displaced towards the front face 114a of the lower rib 114. Thus, the resultant force FR applied to the insert 200 by the charged material typically has a lever effect on the insert 200, which tends to move the rear surface 212 of the protruding part 210 towards the front face 114a of the lower rib 114.

[0056] Over time, the effect of the movement of the insert 200 is to cause wear on the edge of the lower rib 114, particularly at the pivot point P. Moreover, the aforementioned difference between the expansion of the copper alloy of the stave 100 and the expansion of the steel of the mounting part 206 of the insert 200 may cause a loss of contact between the engaging surface of the rear part 204 and the respective wall portion 112b of the groove 112, allowing further rotation of the insert 200. As a result, the insert 200 may loosen from the stave 100 and ultimately become detached from the stave 100.

[0057] Referring now to FIG. 6a, in accordance with the present invention, a rigid brace 300 is positioned between the front face 114a of the upper and lower ribs 114 and the rear surface 212 of the protruding part 210 of the insert 200. In this example, the brace 300 extends downwardly beyond the lower rib 114 (in the Y direction from the top to the bottom in the sense of FIG. 6a).

[0058] In this example, the brace 300 includes a plurality of discrete rigid brace elements arranged opposite to each other. The outer (rear) surface of the first brace element (the leftmost brace element in the sense of FIG. 6a) is in contact with the front surface 114a of the rib 114, while the outer (front) surface of the second outer brace element (the rightmost brace element in the sense of FIG. 6a) is in contact with the rear surface 212 of the protruding part 210. Thus, the gap G is filled or excluded by the brace 300.

[0059] As can be seen in FIG. 6b, the brace element passes through a slot provided in the rear part 204 of the insert 200. The brace element is installed by dropping it into the slot from above either before or after the nut and bolt are tightened to fix the insert 200 in the groove 112. If necessary, the brace element can be gently tapped into place using a mallet or other suitable tool. The upper end of each brace element includes a T-shaped feature to prevent the brace element from falling out of the slot under gravity. The brace elements can all be of the same thickness (in the Z direction in the sense of FIG. 6a), or they can vary in thickness. The number and thickness of the brace elements are appropriately selected to fill or fill the gap G. Although a plurality of brace elements are used to fill the gap G in this example, in other examples, a single brace element of appropriate thickness can be used.

[0060] In this example, each of the brace elements includes sheet steel. Alternative materials include, but are not limited to, copper, copper alloys, and cast iron. The brace elements can include a wear-resistant refractory material. The wear-resistant refractory material can include silicon carbide or alumina. The brace elements can all include the same material, or the materials can vary between the brace elements. For example, the brace element (the leftmost brace element in the sense of FIG. 6a) in contact with the front face 114a of the rib 114 can include a material that is harder than the copper alloy of the stay 100 but softer than the steel of the insert 200.

[0061] Referring again to FIG. 6a, the brace 300 is configured to reduce the lateral distance (in the Z direction from left to right in the sense of FIG. 6a) from the front face 114a of the rib 114 to the rear surface 212 of the protruding part 210 of the insert 200 and to fill the gap G. The brace 300 effectively extends the rib 114 forward so as to reach the rear surface 212. Thus, the brace 300 is arranged to counteract (i.e., oppose) the above-described resultant force FR applied to the insert 200 by the filling material and to resist the displacement of the rear surface 212 of the protruding part 210 toward the front face 114a of the lower rib 114. Thus, the brace 300 prevents or at least limits the movement of the insert 200 relative to the lower rib 114, thereby reducing the wear of the lower rib 114.

[0062] Moreover, the configuration of the brace 300 is such that the pivot point P is effectively moved forward (in the Z direction from left to right in the sense of FIG. 6a), and is positioned adjacent to the rear surface 212 of the protruding part 210 and at the lower end of the outer (front) surface of the second outer brace element. Therefore, the perpendicular distance from the pivot point P to the line of action of the resultant force FR is reduced, thereby reducing the magnitude of the turning moment M (which is the product of the resultant force FR and the perpendicular distance to the pivot point P) compared to the case where there is no brace 300 (as in FIG. 5). That is, the lever effect of the filling material on the insert 200 is reduced by the presence of the brace 300, thereby reducing the risk that the insert 200 will separate from the rib 114 of the stabe 100.

[0063] Therefore, the provision of the brace 300 reduces the wear rate of the rib 114, and thus extends the service life of the stabe 100.

[0064] FIGS. 7a - 7d show another example, which is different from the example described above with respect to the form of the brace. In this example, a single rigid reversible brace 400 is provided between the front face 114a of the rib 114 and the rear surface 212 of the protruding part 210 of the insert 200.

[0065] Referring to FIG. 7a, the reversible brace 400 includes a planar sheet part 402 and a pair of parallel ribs 404 that extend vertically from the planar sheet part 402 to form a channel 406 between the ribs 404. The upper end of the reversible brace 400 includes a T - shaped feature. At the opposite lower end of the reversible brace 400, the ribs 404 are gradually decreasing in height and are tapered at the lower end. The reversible brace 400 can include any of the materials discussed above herein in relation to the brace 300 of FIGS. 6a and 6b.

[0066] Next, referring to FIG. 7b, each of the slots in the rear part 204 of the insert 200 includes a formation 214 that extends inwardly into the slot and has a generally flat surface. The width of the formation 214 is substantially the same as the width of the channel 406 of the reversible brace 400. The width of the slot is substantially the same as the width of the planar sheet part 402 of the reversible brace 400. The depth of the slot (i.e., the depth in a direction perpendicular to the width) is substantially the same as the thickness of the reversible brace 400.

[0067] Now referring to FIGS. 7c and 7d (FIG. 7d is a view from the bottom of the insert 200), the reversible brace 400 is installed into the slot in a first direction. The taper at the lower end of the reversible brace 400 facilitates the entry of the reversible brace 400 into the slot, while the T-shaped feature prevents the reversible brace 400 from falling through the slot. In the first direction, the planar sheet part 402 of the reversible brace 400 is in contact with the generally flat surface of the formation 214 and itself forms the rear surface of the protruding part 210 of the insert 200. The parallel ribs 404 of the reversible brace 400 are in contact with the front face 114a of the ribs 114 of the stabe 100.

[0068] In another arrangement (not shown in the figures), the reversible brace 400 is installed into the slot in a second direction or the reverse direction. The second direction is obtained by rotating the reversible brace 400 180 degrees about its longitudinal axis compared to the first direction. Thus, in the second direction, the planar sheet part 402 of the reversible brace 400 is in contact with the front face 114a of the ribs 114 of the stabe 100, while the parallel ribs 404 are in contact with the rear surface of the protruding part 210 of the insert 200 and the formation 214 is received in the channel 406 (as can be readily understood by assuming a 180-degree reversal of the reversible brace 400 in FIG. 7d).

[0069] Formation 214 is received by channel 406 when the reversible brace 400 is in the second direction, so the size of the gap filled by the reversible brace 400 when the reversible brace 400 is in the second direction is smaller than the size of the gap filled by the reversible brace 400 when the reversible brace 400 is in the first direction. Thus, the reversible brace 400 advantageously provides an efficient means for dealing with gaps of different sizes and enables an operator to select the most appropriate direction of the reversible brace 400 for any given size of gap.

[0070] The reversible brace 400 functions to oppose or repel the resultant force FR applied to the insert 200 by the charging material and, as described above herein, is understood to resist the displacement of the rear surface 212 of the protruding part 210 towards the front surface 114a of the lower rib 114.

[0071] In the example described above, the braces 300, 400 are positioned between the front surface 114a of the upper rib 114 and the rear surface 212 of the protruding part 210 of the insert 200 and between the front surface 114a and the rear surface 212 of the lower rib 114, but in other examples this is not the case. In such examples, the braces 300, 400 are positioned only between the front surface 114a and the rear surface 212 of the lower rib 114.

[0072] In a further example, two separate braces are provided, the first brace being positioned between the front surface 114a and the rear surface 212 of the lower rib 114 and the second brace being positioned between the front surface 114a and the rear surface 212 of the upper rib 114.

[0073] In the examples described above, braces 300, 400 completely fill the gap G between the front face 114a of rib 114 and the rear surface 212 of the protruding part 210 of insert 200. However, in other examples, this is not the case. In such examples, braces 300, 400 are arranged to extend only partway between the front face 114a and the rear surface 212. Thus, braces 300, 400 fit loosely within gap G. In these examples, insert 200 can be moved by the resultant force FR acting on insert 200 by the insertion material to a limited extent, causing the rear surface 212 of the protruding part 210 to contact braces 300, 400, thereby restraining the movement of insert 200 and completely closing gap G. Then, braces 300, 400 will oppose the resultant force FR as described above herein.

[0074] In the examples described above, braces 300, 400 generally comprise pieces of solid material. However, in other examples, the braces take different forms. In one such example, the brace includes an elastic element (e.g., a spring) that is held in a compressed state between the front face 114a of the lower rib 114 and the rear surface 212 of the protruding part 210 of insert 200. The energy stored in the compressed spring causes the spring to expand towards the rear surface 212, for example, by applying a force to the rear surface 212, and said force acts against the resultant force FR acting on insert 200 by the insertion material. All such arrangements and configurations of the brace are within the scope of the claimed invention provided that the brace opposes the resultant force FR so as to resist the displacement of the rear surface of the insert towards the front surface of the lower rib (and optionally the upper rib).

[0075] In the examples described above, the brace generally has a rectangular form and is arranged in a vertical orientation. However, in other examples, the brace is differently shaped and / or arranged. For example, the brace can be C-shaped or horseshoe-shaped and can be installed by moving the brace laterally (horizontally) into the gap G. All such arrangements and configurations of the brace are within the scope of the claimed invention provided that the brace is positioned between the front surface of the lower rib (and optionally the upper rib) and the opposing rear surface of the insert.

[0076] Referring to FIG. 8, in another example, the brace 500 is shaped to resemble a “goal post”. Thus, the brace 500 includes a pair of vertically disposed upright members 502 that are spaced apart from each other and are joined together at their upper ends by a horizontally disposed cross member 504. The brace 500 can include a plurality of discrete rigid brace elements arranged opposite each other or can include a single brace element having a unitary structure. The brace 500 can be constructed from a variety of materials as discussed above herein in connection with other forms of braces.

[0077] Still referring to FIG. 8, the brace 500 is installed by lowering the brace 500 onto the wedge-shaped attachment part 206 of the insert 200 until the cross member 504 contacts the upper surface of the upper rear part 204 of the attachment part 206.

[0078] As can be seen in FIG. 8, in this example, the attachment part 206 is narrower in width than the protruding part 210 of the insert 200 in the transverse direction, and a portion of the rear surface 212 of the protruding part 210 is exposed at each side of the attachment part 206. Thus, in the installed position, the upright member 502 is positioned between the front surface 114a of the lower rib 114 and the rear surface 212 of the protruding part 210. Preferably (as shown in FIG. 8), the lateral spacing between the upright members 502 is substantially equal to the lateral width of the attachment part 206, and the inner edge of each of the upright members 502 is in contact with the outer edge of each side of the attachment part 206. In this way, the brace 500 is prevented from moving left and right in the transverse direction during its service life.

[0079] As can also be seen in FIG. 8, in this example, the cross member 504 lies on the upper surface of the upper rear part 204 and is positioned between the front surface 114a of the upper rib 114 and the rear surface 212 of the protruding part 210. In another example (not shown in FIG. 8), the cross member 504 is received in a shallow transverse groove provided in the upper surface of the upper rear part 204. Thus, in this other example, the cross member 504 is not positioned between the front surface 114a of the upper rib 114 and the rear surface 212 of the protruding part 210. That is, the reason is that it is "hidden" in the groove. Whether the cross member 504 lies on the upper surface of the upper rear part 204 or is alternatively received in a shallow transverse groove provided therein, the cross member 504 is supported by the upper rear part 204, preventing the brace 500 from falling off the assembly under gravity.

[0080] In FIG. 8, the attachment part 206 of the insert 200 is shown as including a vertical slot (as described above herein in connection with other forms of braces), but it will be understood that the slot is not essential to the function of the goal post-shaped brace 500 and can therefore be omitted.

[0081] The brace 500 is described above herein as including straight upright members connected in a vertical manner by straight cross members, but it will be understood that the cross members and even the upright parts can instead be curved such that the brace 500 comes to resemble an inverted U shape or an inverted horseshoe shape.

[0082] In the example described above, the engagement surface of the rear part 204 includes serrations for biting into the copper alloy of the wall part 112b of the groove part 112, but the serrations are not essential to the present invention and in other examples it is omitted.

[0083] It should be understood that the present invention has been described in relation to its preferred embodiments and can be modified in many different ways without departing from the scope of the invention as defined by the appended claims.

Explanation of Reference Numerals

[0084] 100 Stave 102 Front surface, high-temperature surface 104 Rear surface 106a - 106d Edges 110 Water cooling passage 112 Groove part 112a Flat base, flat floor 112b Wall part 114 Rib 114a Rib surface 200 Insert 202 Pin 204 Rear part 206 Attachment part 208 Front part 210 Protruding part 212 Rear surface 214 Formation 300 Brace 400 Reversible brace 402 Planar sheet part 404 Parallel ribs 406 Channel 500 Brace 502 Upright member 504 Cross member FD Downward force FL Lateral force FR Resultant force G Gap L Long axis P Pivot point T Swivel

Claims

1. A stave protection system for a metallurgical furnace, a stave (100) including upper and lower ribs (114), the upper and lower ribs (114) protruding forward from a front face (102) of the stave (100) and being spaced apart from each other to define a transverse groove (112), the stave (100); at least one insert (200), the at least one insert (200) being partially positioned within the groove (112) and fixedly engaged with the upper and lower ribs (114) so as to protrude forward of the upper and lower ribs (114); braces (300; 400; 500), the braces (300; 400; 500) being positioned between a front surface (114a) of the lower rib (114) and an opposing rear surface (212) of the insert (200), and in use, the braces (300; 400; 500) opposing forces (FD, FL, FR) applied to the insert (200) and resisting displacement of the opposing rear surface (212) of the insert (200) toward the front surface (114a) of the lower rib (114); A stave protection system including the above.

2. The stave protection system according to claim 1, wherein the brace (300; 400; 500) extends completely between the front surface (114a) of the lower rib (114) and the opposing rear surface (212) of the insert (200).

3. The stave protection system according to claim 1, wherein the brace (300; 400; 500) extends partially between the front surface (114a) of the lower rib (114) and the opposing rear surface (212) of the insert (200).

4. The brace (300; 400; 500) is further positioned between the front surface (114a) of the upper rib (114) and the opposing rear surface (212) of the insert (200), and during use, the brace (300; 400; 500) resists the forces (FD, FL, FR) applied to the insert (200) and resists the displacement of the rear surface (212) of the insert (200) towards the front surface (114a) of the upper rib (114). The stay protection system according to any one of claims 1 to 3.

5. The brace (300; 500) includes a plurality of discrete brace elements arranged opposite to each other. The stay protection system according to any one of claims 1 to 4.

6. The brace (300; 400; 500) includes a single brace element having a unitary structure. The stay protection system according to any one of claims 1 to 4.

7. The insert (200) A wedge-shaped attachment part (206) that is at least partially received between the opposing inclined wall parts (112b) of the upper and lower ribs (114) so as to be integrated or form a joint, and A protruding part (210) that protrudes in front of the upper and lower ribs (114) and includes the rear surface (212) of the insert (200), and including The attachment part (206) and the brace (300; 400; 500) are configured to engage with each other, and the brace (300; 400; 500) is positioned between the front surface (114a) of the lower rib (114) and the opposing rear surface (212) of the insert (200). The stay protection system according to any one of claims 1 to 6.

8. The brace (300; 400) is received in a slot provided in the attachment part (206), the stabbing protection system according to claim 7.

9. The upper part of the brace (300; 400) is configured to engage with the attachment part (206) so as to prevent the brace (300; 400) from falling out of the slot, the stabbing protection system according to claim 8.

10. The rear surface (212) of the insert (200) includes a generally flat formation (214) extending into the slot, The brace (400) includes a planar sheet part (402) and parallel ribs (404), the parallel ribs (404) extending vertically from the planar sheet part (402) and forming a channel (406) between the parallel ribs (404), The brace (400) is selectively reversible between a first orientation and a second orientation, In the first orientation, the planar sheet part (402) faces the flat formation (214), and the parallel ribs (404) face the front surface (114a) of the lower rib (114), In the second orientation, the planar sheet part (402) faces the front surface (114a) of the lower rib (114), and the flat formation (214) is received in the channel (406) between the parallel ribs (404), The brace (400) thereby spans a greater distance between the front surface (114a) of the lower rib (114) and the flat formation (214) in the first orientation than in the second orientation, the stabbing protection system according to claim 8 or 9.

11. The lateral width of the attachment part (206) is smaller than the lateral width of the protruding part (210), The brace (500) includes first and second upright members (502), the first and second upright members (502) being spaced apart laterally from each other and joined by a cross member (504), the cross member (504) extending laterally along an upper surface of the attachment part (206) and being supported thereby, each of the first and second upright members (502) being subordinate to respective ends of the cross member (504) and adapted to extend along respective sides of the attachment part (206). The stab protection system according to claim 7.

12. The lateral spacing between the upright members (502) is substantially equal to the lateral width of the attachment part (206), and inner edges of each of the upright members (502) are in contact with outer edges of respective sides of the attachment part (206), thereby suppressing lateral movement of the brace (500) relative to the insert (200). The stab protection system according to claim 11.

13. A plurality of said inserts (200), A plurality of said braces (300; 400) respectively positioned between a front surface (114a) of the lower rib (114) and one respective opposing rear surface (212) of a plurality of said inserts (200), The stab protection system according to any one of claims 1 to 12, comprising.

14. A kit of parts for a stab protection system according to any one of claims 1 to 12, At least one of said inserts (200) for said engagement with the upper and lower ribs (114) of the stab (100), At least one of said braces (300; 400) for disposition between the front surface (114a) of the lower rib (114) of the stab (100) and the one respective opposing rear surface (212) of said at least one of said inserts (200), A kit comprising

15. A method of installing the stabbing protection system according to any one of claims 1 to 12, fixedly attaching the insert (200) to the upper and lower ribs (114) of the stabbing (100); selecting a brace (300; 400) of appropriate thickness according to the distance between the front surface (114a) of the lower rib (114) and the opposing rear surface (212) of the insert (200); disposing the brace (300; 400) between the front surface (114a) of the lower rib (114) and the opposing rear surface (212) of the insert (200); A method comprising

16. The step of disposing the brace (300; 400) between the front surface (114a) of the lower rib (114) and the opposing rear surface (212) of the insert (200) includes disposing the brace (300; 400) so as to extend completely between the front surface (114a) of the lower rib (114) and the opposing rear surface (212) of the insert (200). The method according to claim 15.

17. The step of disposing the brace (300; 400) between the front surface (114a) of the lower rib (114) and the opposing rear surface (212) of the insert (200) includes disposing the brace (300; 400) so as to extend partially between the front surface (114a) of the lower rib (114) and the opposing rear surface (212) of the insert (200). The method according to claim 15.

18. The method according to any one of claims 15 to 17, further comprising the step of disposing the brace (300; 400) between the front surface (114a) of the upper rib (114) and the opposing rear surface (212) of the insert (200).

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