Sealing method for precast refractory blocks for coke ovens

Abstract

To provide a seal construction method for a precast refractory block for coke ovens, whereby, when forming a joint by pouring mortar into a space between the precast refractory block for coke ovens with opening grooves and a retaining wall of a coke oven, it is possible to prevent the mortar from flowing into the opening grooves, and to successfully form the joint between the precast refractory block for the coke oven and the retaining wall.SOLUTION: There is provided a seal construction method for a precast refractory block for a coke oven. When installing a precast refractory block 7 having an opening groove 7a extending in a vertical direction into a space adjacent to a furnace inner wall surface 5a of a retaining wall 5 of the coke oven, the method is configured to execute following steps of: installing the precast refractory block 7 so that the opening groove 7a faces the furnace inner wall surface 5a of the retaining wall 5 and has a clearance W1 between the block and the furnace inner wall surface 5a of the retaining wall 5; inserting a sponge 8 having a back plate 9 into the opening groove 7a with the sponge 8 side facing toward the furnace inner wall surface 5a of the retaining wall 5; inserting a wedge 10 between the inner wall surface of the opening groove 7a and a back plate 9; and pouring mortar into the clearance W1.SELECTED DRAWING: Figure 9

Description

[Technical Field]

[0001] The present invention relates to a method for sealing precast refractory blocks for coke ovens. [Background technology]

[0002] In a coke oven, also known as a chamber-hearth coke oven, coke chambers and combustion chambers are arranged alternately across the oven width, with the oven top above the coke chambers and combustion chambers and the regenerator below them. Concrete retaining walls are installed at both ends of the oven width to support the brickwork between them. As such, the retaining walls of coke ovens are made of concrete, which has low heat resistance and is prone to deterioration when exposed to high temperatures for long periods of time. Therefore, vertically extending ducts are sometimes installed as hollow spaces through which air can circulate between the retaining wall and the brick structure (for example, Patent Document 1). This duct was constructed by hand, laying each silica brick by hand. However, this method requires a huge number of skilled bricklayers, as it requires applying mortar to each brick to form joints between the bricks, and in recent years it has become difficult to secure a sufficient number of bricklayers.

[0003] Therefore, in recent years, in order to construct a coke oven with a small number of people, a method of constructing a coke oven by installing large precast refractory blocks has been adopted (for example, Patent Document 2). When constructing the above-mentioned duct using this method, an open groove that will become the duct is formed in the precast refractory block in advance. Then, the precast refractory block for the coke oven is installed so that the open groove faces the furnace-side wall surface of the retaining wall and there is a gap between the open groove and the furnace-side wall surface of the retaining wall, and then mortar is poured into the gap. However, since the precast refractory blocks have opening grooves facing the furnace-side wall surface of the retaining wall, when mortar is poured into the gaps, the mortar flows into the opening grooves, making it difficult to properly form joints between the precast refractory blocks and the retaining wall. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-187218 [Patent Document 2] Japanese Patent Application Publication No. 2020-8197 Summary of the Invention [Problem to be solved by the invention]

[0005] The problem to be solved by the present invention is to provide a sealing construction method for precast refractory blocks for coke ovens, which prevents mortar from flowing into the open grooves when mortar is poured into the gap between the precast refractory block for coke ovens having open grooves and the retaining wall of the coke oven to form a joint, and which can successfully form a joint between the precast refractory block for coke ovens and the retaining wall. [Means for solving the problem]

[0006] According to one aspect of the present invention, there is provided the following method for sealing precast refractory blocks for a coke oven. A method for sealing precast refractory blocks for a coke oven, which are installed adjacent to an inner wall surface of a retaining wall of the coke oven, comprising the steps of: The precast refractory block for a coke oven has an open groove extending in a vertical direction, a step of installing the precast refractory block for a coke oven so that the opening groove faces the furnace-side wall surface of the retaining wall and has a gap between the opening groove and the furnace-side wall surface of the retaining wall; Inserting a sponge having a back plate into the open groove with the sponge side facing the furnace-side wall surface of the retaining wall; inserting a wedge between the inner wall surface of the opening groove and the back plate; and pouring mortar into the gap between the furnace-side wall surface of the retaining wall and the precast refractory block for the coke oven. [Effects of the Invention]

[0007] According to the sealing construction method for precast refractory blocks for coke ovens of the present invention, when mortar is poured into the gap between a precast refractory block for a coke oven having an open groove and the retaining wall of the coke oven to form a joint, the mortar can be prevented from flowing into the open groove, and a joint can be successfully formed between the precast refractory block for a coke oven and the retaining wall. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view conceptually showing the structure of a coke oven. [Figure 2A] FIG. 1 is a perspective view conceptually showing the arrangement of retaining walls and backstays of a coke oven. [Figure 2B] FIG. 1 is a schematic plan view conceptually showing the arrangement of retaining walls and backstays of a coke oven. [Figure 3] FIG. 2 is a perspective view of a precast refractory block for a coke oven, which is installed adjacent to the furnace inner wall surface of the retaining wall of the coke oven. [Figure 4A] FIG. 1 is a perspective view showing a state in which a plurality of precast refractory blocks are arranged in the furnace length direction adjacent to the furnace inner wall surface of the retaining wall of a coke oven. [Figure 4B] A plan view showing a state in which multiple precast refractory blocks are arranged in the furnace length direction adjacent to the furnace inner wall surface of the retaining wall of a coke oven. [Figure 5A] FIG. 10 is a perspective view showing a state in which a sponge having a back plate is inserted into an open groove of a precast fire-resistant block. [Figure 5B] 1 is a plan view showing a state in which a sponge with a back plate is inserted into an open groove of a precast fire-resistant block. [Figure 6] 1A shows a sponge with a back plate, (a) is a plan view, (b) is a front view, and (c) is a side view. [Figure 7]FIG. 10 is a plan view showing a state in which a wedge is inserted between the inner wall surface of the opening groove of the precast refractory block for a coke oven and the back plate. [Figure 8] The wedge is shown in (a) front view and (b) side view. [Figure 9] A plan view showing the state in which mortar has been poured into the gap between the inner wall surface of the coke oven retaining wall and the back surface of the precast refractory blocks for the coke oven, and into the gap between the sides of the precast refractory blocks for the coke oven arranged in the direction of the oven length. DETAILED DESCRIPTION OF THE INVENTION

[0009] Fig. 1 conceptually shows the structure of a coke oven, and Fig. 2A and Fig. 2B conceptually show the arrangement of the retaining walls and backstays of the coke oven. In the coke oven A, the coking chambers 1 and the combustion chambers 2 are arranged alternately in the oven width direction X, with the oven top 3 above the coking chambers 1 and the combustion chambers 2 and the regenerators 4 below. Concrete retaining walls 5 are provided at both ends in the oven width direction X, and serve to retain the refractory structure between the two retaining walls 5, 5. In addition, backstays 6a, 6b are installed facing each other on the outside of the oven at both ends in the oven length direction Y of the coke oven A to apply oven clamping force to the refractory structure.

[0010] Fig. 3 is a perspective view showing a precast refractory block for a coke oven installed adjacent to the furnace-side wall surface 5a of the retaining wall 5. Fig. 4A and Fig. 4B show a state in which a plurality of precast refractory blocks for a coke oven are arranged in the furnace length direction Y adjacent to the furnace-side wall surface 5a of the retaining wall 5. Here, the precast refractory block is a refractory block obtained by adding water to a granular refractory composition, kneading the mixture, pouring it into a formwork, and drying it. Typical precast refractory blocks for coke ovens include fused silica precast refractory blocks and clay precast blocks. The fused silica precast refractory block is a precast refractory block obtained by blending fused silica as the main raw material in the raw material composition of the refractory composition. The clay precast refractory block is a precast refractory block obtained by blending chamotte as the main raw material in the raw material composition of the refractory composition. In the following description, the "precast refractory block for coke oven" will be simply referred to as the "precast refractory block."

[0011] As shown in Figure 3, the precast refractory block 7 has four vertically extending open grooves 7a on its back surface, which faces the furnace-side wall surface 5a of the retaining wall 5. Here, the open grooves refer to the grooves that open on the back surface of the precast refractory block. Furthermore, the vertical direction refers to the furnace height direction Z in terms of the direction of the coke oven A. The precast refractory block 7 also has mounting holes 7b on its top surface for attaching a hanging ring that connects to a lifting tool when the block is lifted with the lifting tool and moved to the specified installation position.

[0012] Below, an embodiment of the sealing construction method for precast refractory blocks of the present invention will be described, taking as an example the case where the precast refractory block 7 shown in Figure 3 is installed adjacent to the furnace inner wall surface 5a of the retaining wall 5 of a coke oven A. In Figures 4A and 4B and Figures 5A and 5B described below, the precast refractory block 7 installed at one end of the coke oven in the furnace length direction Y has two opening grooves 7a, which is different from Figure 3, but in the following explanation no distinction will be made and both will be described as precast refractory block 7. In this embodiment, the open groove 7a is provided on one side of the precast refractory block 7. In other words, the upper end, lower end, and one side of the precast refractory block 7 are open. The open groove 7a is continuous over the entire length of the precast refractory block 7 from the upper end to the lower end.

[0013] 4A and 4B, in this embodiment, a step of installing a plurality of precast refractory blocks 7 is carried out so that the opening grooves 7a face the furnace-inside wall surface 5a of the retaining wall 5 and a gap W1 is formed between the opening grooves 7a and the furnace-inside wall surface 5a of the retaining wall 5. In this step, the plurality of precast refractory blocks are arranged in the furnace length direction Y with a gap W2 between them.

[0014] Next, as shown in FIGS. 5A and 5B, a step of inserting the sponge 8 having the back plate 9 into the open groove 7a with the sponge 8 side facing the furnace-side wall surface 5a of the retaining wall 5 is carried out. Here, the sponge 8 and the back plate 9 are configured to be longer than the entire length of the opening groove 7a of the precast refractory block 7. The sponge 8 is in contact with two of the inner walls of the precast refractory block 7 that form the opening groove 7a, which are in the furnace length direction Y of the coke oven. These two inner walls and the sponge 8 are in contact with each other over the entire length of the precast refractory block 7, from the top end to the bottom end.

[0015] 6, the sponge 8 is bonded to the rear surface of the back plate 9 by, for example, an adhesive, thereby forming a structure having the back plate 9. The sponge 8 itself is made of, for example, polyurethane foam, and the back plate 9 is made of, for example, plywood, but the materials of the sponge 8 and the back plate 9 are not limited to these. On the other hand, a wedge receiving plate 9a having an inclined receiving surface 9a-1 that mates with the inclined surface of the wedge (described later) is attached to the front of the back plate 9 with screws 9b. The wedge receiving plate 9a is also made of, for example, plywood. In this embodiment, as shown in Fig. 5A, the sponge 8 with the back plate 9 is inserted so that the upper part of the wedge receiving plate 9a of the back plate 9 and the upper part of the sponge 8 protrude from the upper end of the opening groove 7a.

[0016] After the step of inserting the sponge 8 with the back plate 9 into the opening groove 7a is completed, the step of inserting the wedge 10 between the inner wall surface of the opening groove 7a and the back plate 9 is carried out as shown in Fig. 7. Note that the masking tape 12 shown in Fig. 5A is omitted in Fig. 7. As shown in Figure 8, the wedge 10 has a plate-like shape and a sloped surface 10a extending along the entire length of the front side, where the thickness of the wedge 10 decreases toward its tip. When inserting the wedge 10, the sloped surface 10a is inserted so that it faces the sloped support surface 9a-1 formed on the front of the wedge support plate 9a of the back plate 9. The length and width of the wedge 10 (sloped surface 10a) are the same as those of the wedge support plate 9a (sloped support surface 9a-1), and the sloped support surface 9a-1 is sloped so that the thickness of the wedge support plate 9a increases toward its tip. Therefore, by inserting the wedge 10 so that the sloped surface 10a of the wedge 10 faces the sloped support surface 9a-1 of the back plate 9, the wedge effect of the wedge 10 pressing the sponge 8 toward the furnace-side wall surface 5a of the retaining wall 5 is reliably and uniformly achieved along the entire length of the back plate 9. However, the shapes of the back plate 9 and the wedge 10 are not limited to those of this embodiment, and in short, they may have any shape that provides a wedge effect to the sponge 8 when the wedge 10 is inserted between the inner wall surface of the opening groove 7a and the back plate 9.

[0017] After inserting the wedges 10, as shown in FIG. 9, mortar 11 is poured into the gaps W1 between the furnace-side wall surface 5a of the retaining wall 5 and the back of the precast refractory blocks 7, and into the gaps W2 between the side surfaces of the precast refractory blocks 7 arranged in the furnace length direction Y. Prior to this process, as shown in FIG. 5A, appropriate areas are covered with masking tape 12 to prevent mortar from leaking out of the gaps W1 and W2. Mortar is then poured into the gaps W1 and W2 to form joints. As shown in FIGS. 7 and 9, the sponge 8 is pressed between the opening of the groove 7a and the furnace-side wall surface 5a of the retaining wall 5 by the wedge effect of the wedges 10. This prevents mortar 11 from flowing into the groove 7a, ensuring a smooth joint between the precast refractory blocks 7 and the retaining wall 5.

[0018] Once the mortar 12 has hardened, the sponge 8 with the back plate 9 and the wedge 10 are pulled out from the open groove 7a. In this embodiment, as shown in Figures 6 and 8, a connecting fitting 9c is provided on the back plate 9 and a connecting fitting 10b is provided on the wedge 10, and the connecting fitting 9c and the connecting fitting 10b are connected with a connecting string (not shown), thereby connecting the back plate 9 and the wedge 10 with the connecting string. This makes it possible to prevent problems such as the wedge 10 falling into the open groove 7a and becoming impossible to retrieve when the sponge 8 with the back plate 9 and the wedge 10 are pulled out from the open groove 7a after the mortar 12 has hardened.

[0019] Once the installation of the first tier of precast fireproof blocks 7 is completed in this manner, the installation of the second tier of precast fireproof blocks 7 is carried out. To install the second tier of precast fireproof blocks 7, precast fireproof blocks 7 of the same shape are placed on top of the precast fireproof blocks 7 of the first tier, and the installation is carried out in the same manner as the installation of the first tier of precast fireproof blocks 7. The installation of the precast fireproof blocks 7 from the third tier onwards is carried out in the same manner. Once the installation of the top tier of precast fireproof blocks 7 is completed in this manner, the open grooves 7a of the precast fireproof blocks 7 of each tier will be connected vertically, and a duct extending vertically will be formed as a cavity through which air can circulate between the retaining wall 7 and the structure of precast fireproof blocks 7.

[0020] As described above, according to this embodiment, when mortar 11 is poured into the gap W1 between the precast refractory block 7 having the opening groove 7a and the retaining wall 5 of the coke oven to form a joint, the mortar 11 is prevented from flowing into the opening groove 7a, and a joint can be successfully formed between the precast refractory block 7 and the retaining wall 5. In addition, in this embodiment, the wedge 10 is inserted so that the inclined surface 10a of the wedge 10 faces the inclined receiving surface 9a-1 of the back plate 9, so that the wedge effect caused by the insertion of the wedge 10 is obtained reliably and evenly over the entire length of the back plate 9. [Explanation of symbols]

[0021] A Coke oven X Furnace width direction Y Furnace length direction Z Furnace method W1, W2 gap 1 carbonization chamber 2. Combustion chamber 3 Furnace top 4 Heat storage chamber 5. Retaining walls 5a Furnace-side wall of retaining wall 6a, 6b Backstay 7 Precast refractory blocks 7a Opening groove 7b Mounting hole 8. Sponge 9 Back plate 9a Wedge support plate 9a-1 Inclined receiving surface 9b Bis 9c Connector 10 Wedge 10a Slope 10b Connector 11 Mortar 12 Masking tape

Claims

1. A method for sealing precast refractory blocks for a coke oven, which are installed adjacent to an inner wall surface of a retaining wall of the coke oven, comprising the steps of: The precast refractory block for a coke oven has an open groove extending in a vertical direction, a step of installing the precast refractory block for a coke oven so that the opening groove faces the furnace-side wall surface of the retaining wall and has a gap between the opening groove and the furnace-side wall surface of the retaining wall; Inserting a sponge having a back plate into the open groove with the sponge side facing the furnace-side wall surface of the retaining wall; inserting a wedge between the inner wall surface of the opening groove and the back plate; and pouring mortar into the gap between the furnace-side wall surface of the retaining wall and the precast refractory block for the coke oven.

2. The wedge has an inclined surface that is inclined so that the thickness of the wedge decreases toward the tip of the wedge, and the back plate is provided with an inclined receiving surface that faces the inclined surface, 2. The seal construction method for precast refractory blocks for a coke oven according to claim 1, wherein in the step of inserting the wedge, the wedge is inserted so that the inclined surface of the wedge faces the inclined receiving surface of the back plate.

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