FLUE block with access port for a heating wall of a COKE oven battery

Abstract

A flue block for a heating wall of a coke oven having a first passageway disposed between a top face and a bottom face with respective openings within the faces, a second passageway disposed between the top and bottom faces having respective openings within the faces, a first conduit disposed within the first passageway and having a third passageway therein, a second conduit disposed within the second passageway and having a fourth passageway therein, a first access port disposed within one of a pair of side faces and in communication with the first passageway, and a second access port disposed within one of the side faces and in communication with the second passageway, wherein each of the access ports are arranged to accept a plug therein. In some embodiments, the plugs are tapered. Also disclosed is a heating wall for a coke oven.

Description

FLUE BLOCK WITH ACCESS PORT FOR A HEATING WALL OF A COKE OVEN BATTERYCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application No. 63 / 725,622, filed November 27, 2024, which application is incorporated by reference herein in its entirety.FIELD

[0002] The present invention relates to coke ovens, and more particularly, to a flue block for a heating wall of a coke oven and a heating wall of a coke oven.BACKGROUND

[0003] Coke is a high-strength, solid carbon fuel produced by heating coal in a coke oven at high temperatures, a process known as coking. Coke oven batteries are typically comprised of numerous coking chambers separated by heating walls. These heating walls are traditionally constructed by stacking hundreds or thousands of individual silica bricks, or blocks, to form multiple vertical tiers. The stacked blocks define internal vertical passageways, known as flues, through which hot gases flow to heat the coal in the adjacent chambers.

[0004] The construction and repair of these brick-built heating walls present significant challenges. The process is labor-intensive, and the vast number of joints between the individual bricks creates numerous potential failure points for gas leakage as the oven ages and degrades from thermal cycling.

[0005] A more immediate problem occurs during construction or repair. As the tiers of the heating wall are built upward, excess mortar, brick fragments, and occasionally tools can fall down into the flues. This debris accumulates at the bottommost tiers of the heating wall, where it can obstruct gas flow, impair combustion, and create operational hazards. While mesh screens are sometimes installed at low levels to catch this debris, these screens are typically incinerated during the oven's initial heat-up, potentially leaving the collected debris behind. Removing this debris after the wall is complete is difficult and often impractical.

[0006] Thus, there is a continuing need for advancements in coke oven heating wall technologyCITATIONS

[0007] The following patent and patent applications are incorporated by reference herein in their entireties: U.S. Patent Application No. 18 / 701,487, filed April 15, 2024, U.S. Patent Application No. 18 / 701,468, filed April 14, 2024, U.S. Patent No. 8,640,635, issued February 4, 2014.SUMMARY

[0008] According to aspects herein, the present invention comprises a flue block for a heating wall of a coke oven, the flue block may comprise a top face, a bottom face, a first side face, a second side face, a first end, and a second end, a first passageway disposed between the top and bottom faces having respective openings within the top and bottom faces, a second passageway disposed between the top and bottom faces having respective openings within the top and bottom faces, a first conduit disposed within the first passageway and having a third passageway therein, the third passageway having respective openings within the top and bottom faces, a second conduit disposed within the second passageway and having a fourth passageway therein, the fourth passageway having respective openings within the top and bottom faces, a first access port disposed within one of side faces and in communication with the first passageway, thereby forming a fifth passageway, and a second access port disposed within one of side faces and in communication with the second passageway, thereby forming a sixth passageway, wherein each of the access ports are arranged to accept a plug therein.

[0009] In some embodiments, the first end comprises a protruding portion extending therefrom and the second end comprising a recessed portion arranged therein.

[0010] In other configurations, the aforementioned flue block may further include a first groove and a second groove disposed within the top face, each groove being proximate one of the sidewalls and extending from the first end to the second end, a first protrusion and a second protrusion extending from the bottom face, each protrusion being proximate one of the sidewalls and extending from the first end to the second end.

[0011] In other embodiments, the aforementioned flue block may further comprise a first plug adapted to be inserted into the first access port, and a second plug adapted to be inserted into the second access port.

[0012] In some possible embodiments, the fifth passageway is tapered and the sixth passageway is tapered.

[0013] In further configurations, the first conduit includes a recessed portion disposed within the top face and the second conduit includes a recessed portion disposed within the top face, and the first conduit includes a protruding portion extending from the bottom face and the second conduit includes a protruding portion extending from the bottom face.

[0014] In further embodiments, the aforementioned flue block may also include a first plug adapted to be inserted into the first access port, the first plug being tapered such that it can be seated within the first access port, and a second plug adapted to be inserted into the second access port, the second plug being tapered such that it can be seated within the first access port.

[0015] In one possible design, the aforementioned flue block may further comprise a pass- through riser extending from one or more of the first conduit or the second conduit.

[0016] In some aspects, the present invention may relate to a flue block for a heating wall of a coke oven, the flue block comprising a first passageway disposed between a top face and a bottom face, the first passageway having respective openings within the top and bottom faces, a second passageway disposed between the top and bottom faces having respective openings within the top and bottom faces, one or more access ports disposed within one of a pair of side faces and in communication with one or more of the first passageway or the second passageway, thereby forming one or more access passageways, and where each of the one or more access passageways are arranged to accept a plug therein.

[0017] In some embodiments, each of the one or more access passageways is tapered, and each of the one or more plugs are tapered.

[0018] In other possible embodiments, the aforementioned flue block may further include a first access port disposed within one of the pair of side faces and in communication with the first passageway, thereby forming a first access passageway, and a second access port disposed within the other of the pair of side faces and in communication with the second passageway, thereby forming a second access passageway.

[0019] In some possible configurations, the first access passageway is tapered, and the second access passageway is tapered.

[0020] In further embodiments, the aforementioned flue block may further comprise a first plug adapted to be inserted into the first access passageway, the first plug being tapered in relation to the taper of the first access passageway such that it may be seated therein, and a second plug adapted to be inserted into the second access passageway, the second plug being tapered in relation to the taper of the second access passageway such that it may be seated therein.

[0021] In other aspects, the present invention may relate to a heating wall for a coke oven, where the heating wall comprises a plurality of flue blocks forming a wall with a plurality of tiers, each tier defined by one or more flue block of the plurality of flue blocks stacked in a vertical direction, one or more passageways within the wall formed by one or more passageways within each of the flue blocks, and one or more access ports in communication with the one or more passageways of at least one flue block of the stacked plurality of flue blocks, wherein each of the one or more access ports are adapted to accept a plug therein.

[0022] In some embodiments, each tier of the plurality of tiers comprises one or more flue blocks of the plurality of flue blocks abutting an adjacent flue block.

[0023] In other possible configurations, the one or more access ports are arranged within a bottommost tier of the plurality of tiers.

[0024] In other embodiments, the one or more access ports are arranged within at least one flue block of the plurality of flue blocks of one or more of a bottommost tier of the plurality of tiers or stacked directly above the bottommost tier of the plurality of tiers.

[0025] In further embodiments, each of the one or more access ports are adapted to accept a plug therein.

[0026] In one possible design, the aforementioned heating wall further includes one or more plugs arranged to be inserted into the one or more access ports.

[0027] In further configurations, each of the one or more access ports are tapered.

[0028] In a possible alternative embodiment, the one or more access ports of the aforementioned heating wall for a coke are arranged within an access flue block of the plurality of flue blocks, wherein the access flue block may comprises a first passageway disposed between a top face and a bottom face, the first passageway having respective openings within the top and bottom faces, a second passageway disposed between the top and bottom faces having respective openings within the top and bottom faces, a first conduit disposed within the first passageway and having a third passageway therein, the third passageway having respective openings within the top and bottom faces, a second conduit disposed within the second passageway and having a fourth passageway therein, the fourth passageway having respective openings within the top and bottom faces, a first access port disposed within one of side faces and in communication with the first passageway, thereby forming a fifth passageway, and a second access port disposed within one of side faces and in communication with the second passageway, thereby forming a sixth passageway, wherein each of the access ports are arranged to accept a plug therein.

[0029] These and other objects, features, and advantages of the present invention will become readily apparent upon a review of the following detailed description of the present disclosure, in view of the drawings and appended claims.BRIEF DESCRIPTION

[0030] Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which: Figure 1 generally shows an isometric and partial cut-away view of an exemplary embodiment of a coke oven; Figure 2 is an enlarged portion generally taken from DETAIL 1 in Figure 1; Figure 3 generally shows a top perspective view of an access flue block; Figure 4 generally shows an exploded view of the block shown in Figure 3; Figure 5Agenerally shows a bottom perspective view of the block shown in Figure 3; Figure 5B generally shows a top plan view of the block shown in Figure 3; Figure 5C generally shows a left-side view of the block shown in Figure 3; Figures 5D and 5E are enlarged portions taken generally from Figure 5B; Figure 6A and 6B generally show perspective views of the plug shown in Figure 4; Figure 6C generally shows a top plan view of the plug shown in Figure 6A; Figure 7 generally illustrates an alternative embodiment of the block shown in Figure 3; and, Figure 8 generally shows a representative stacking and abutting pattern of a plurality of flue blocks to form the heating wall shown in Figures 1 and 2.DETAILED DESCRIPTION

[0031] At the outset, it should be understood that like reference numbers on different drawing views identify identical or functionally similar structural elements. The detailed description that follows is intended to be illustrative and not restrictive. The scope of the invention is defined by the appended claims, and this disclosure is not limited to the specific methodologies, materials, or exemplary embodiments described herein, as these may vary. Any implementation described as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations.

[0032] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Terms such as “comprising,” “including,” and “having” are to be interpreted as open-ended, meaning they do not exclude the presence of additional, unrecited elements or steps. Furthermore, if a component or feature is described using conditional language such as “may,” “can,” “could,” “should,” or “preferably,” that component or feature is not required and may be optionally included. Terms of degree, such as “substantially,” “proximate,” or “approximately,” are intended to be interpreted with a reasonable breadth. For instance, “approximately” may refer to values within ten percent of the stated value, unless the context dictates otherwise.

[0033] It should also be understood that logical conjunctions are used in their inclusive sense unless stated otherwise. The word “or,” when used in a list of items, means that any one of the items may be present, or any combination of the items may be present. For example, a statement that “item x is A or B” is satisfied if item x is A, if item x is B, or if item x is both A and B. Similarly, the phrase “at least one of’ in combination with a list of elements means that the system or element includes one or more of the elements from that list, taken individually or in any combination.

[0034] As used herein, the terms “fluid communication”, “communication”, and / or substantial equivalents thereof, are meant to mean two or more components are connected, e.g.,“fluidly connected”, “fluid connection”, etc., such that a substance, e.g., gases, fluid, etc., can flow between and / or within the two components. “Fluid communication”, “communication”, and / or equivalents thereof, are also intended to include heat transfer between two or more components.COKE OVEN

[0035] Adverting now to the figures, Figure 1 is isometric and partial cut-away view of an exemplary embodiment of a coke oven and Figure 2 is an enlarged view of a portion thereof, particularly, a gun-fire style coke oven, and more specifically, a single coke oven of a battery of coke ovens, coke oven 10, in accordance with embodiments of the technology and where the present invention may be deployed. As discussed supra, the battery may have anywhere from 20 to over 100 side-by-side coking chambers, or ovens, separated from each other by heating walls, e.g., multiples of coke oven 10 arranged side-by-side. It should be appreciated that the present invention may readily be modified or adapted for use in any style of coke oven.

[0036] Coke oven 10 includes regenerator 14 which may be formed a plurality of piers or pillars formed by stacking pier blocks 16 or pillar blocks, which are spaced apart to form regenerator regions between the stacks, pier blocks 16 support corbels 18. Each of corbels 18 comprise one or more blocks, corbel blocks 20 and 22, which support gun block 24. In some configurations, corbels 18 comprise a plurality of blocks arranged in a plurality of tiers.

[0037] Corbels 18 are arranged on top of the stacked pier blocks 16 and support the oven section of coke oven 10. Specifically, corbels 18 support floor 26, heating walls 34, and coal placed in oven 12, allowing air to flow between flues 36 and 38 and regenerator 14, and / or allow gas to be injected into flues 36 and 38. For example, gas or fuel is injected into corbels 18 horizontally via a hole or through-bore of gunblock 24 and flows vertically therethrough and into flues 36 and 38. Air flows up through corbel 18, particularly through passageway 72 being in fluid communication with regenerator 14, which may be arranged in one or more of corbel blocks 20 or 22, and into flues 36 and 38 where it mixes with the fuel and combusts in heat heating wall 34, thus cooking the coal arranged in oven 12, transforming it into coke.

[0038] Exhaust gases are created from such combustion, these hot exhaust gases may flow down through one or more of flues 36 or 38 and into regenerator 14, thereby preheating the incoming gas and / or air. Preheating gas and / or air as it flows into flues 36 and 38 prior to combustion is desirable because it produces more efficient vaporization and higher combustion efficiency than cold fuel.

[0039] Heating wall 34 is formed by stacking and abutting a plurality of flue blocks, e.g., flue blocks 40-66, and 100, thereby forming a plurality of tiers. Each of flue blocks 40-66, and100 comprise one or more apertures therein, apertures 74, 76, 78, and 80. When apertures 74 and 76 are stacked, via each tier formed by a flue block, they form flues 36 and 38, when the stacks of flue blocks are abutted along longitudinal directions LD1 and LD2, there are a plurality of flues along longitudinal directions LD1 and LD2 of heating wall 34. Apertures 78 and 80 of a particular flue bock, when stacked form pass-through risers 68 and 70, where the risers have terminating openings at a selectable tier within each of flues 36 and 38. In other words, only some of the flue blocks within heating wall 34 have apertures 78 and 80, preferably within one or more tiers of the flue blocks proximate floor 28.

[0040] In accordance with the technology of the present disclosure, apertures 74 and 76 are in communication with regenerator 14 and apertures 78 and 80 are in communication with one or more of gunblock 24. In other words, apertures 78 and 80 form a gas conduit from corbel 18 into flues 36 and 38 and apertures 74 and 76 form an air / gas exhaust conduit from heating wall 34 and regenerator 14.ACCESS FLUE BLOCK

[0041] Adverting now to Figures 3 through 6C, which describe access flue block 100 and components thereof. In reference to Figures 1 and 2, access flue block 100 is one of many flue blocks which form heating wall 34 of coke oven 10. In a preferred embodiment of heating wall 34, access flue block 100 is the bottommost flue block, or one of the first tiers of heating wall 34 proximate floor 28.

[0042] Access flue block 100 may include front face 102, rear face 104, top face 106 (or top surface), bottom face 108 (or bottom surface), side face 110, and side face 112. Generally, opposite faces are parallelly arranged, e.g., front face 102 and rear face 104, top face 106 and bottom face 108, side face 110 and side face 112, and preferably, the respective faces are planar, specifically, top face 102 and rear face 104 to provide a consistent and level surface for other flue blocks (e.g., flue block 44) to be stacked thereon. In a preferred configuration, access flue block 100 is a single integrally formed element, i.e., monolithic, as access flue block 100 must be comprised of a material composition that can withstand at least l,800°F without deformation or deterioration — although access flue block 100 may be configured with separate components that are fixedly secured thereto, discussed further infra. It should be appreciated that access flue block 100 is comprised of a material composition that can withstand the aforementioned temperature minimum during daily operation of the coke oven battery for a minimum of 20 years. Preferably, the material composition of access flue block 100 comprises approximately 90%, or greater, of SiO2 (Silicon Dioxide) and has a modulus of rupture of approximately 6.9 MPa (MegaPascal) at 1090°C and 3.5 MPa at 1480°C. However, one having skill in the art andin accordance with the technology of the disclosure will understand that any suitable material or composition, now known or hereafter developed, may be used in forming the access flue block, and the aforementioned material compositions should not be considered restrictive on the scope of the appending claims.

[0043] Flue apertures 118 and 120 are arranged within top face 106 and bottom face 108, such that each of flue apertures 118 and 120 has an opening disposed within both of top face 106 and bottom face 108. As shown, flue apertures 118 and 120 are spaced apart and bifurcated proximate a middle area between side faces 110 and 112. Flue apertures 118 and 120 having inner walls 142 and 144, respectively. Pass-through aperture 124 is arranged within body 138, where body 138 protrudes or extends from inner wall 142 of flue aperture 120. Body 138 may form one tier of riser 68 shown in Figure 2, preferably the bottommost tier of riser 68. Pass- through aperture 124 has an opening disposed within both of top face 106 and bottom face 108 of body 138. Pass-through aperture 122 is arranged within body 140, where body 140 protrudes or extends from inner wall 144 of flue aperture 118. Body 140 may form one tier of riser 70 shown in Figure 2, preferably the bottommost tier of riser 70. Pass-through aperture 122 has an opening disposed within both of top face 106 and bottom face 108 of body 140.

[0044] As shown in Figure 3 and in a preferred embodiment, the opening of pass-through aperture 124 disposed within top face 106, is arranged within recess 146 of body 138. As shown in Figure 5A and in a preferred embodiment, the opening of pass-through aperture 124 disposed within bottom face 108, is arranged with protruding portion 168 of body 138. As shown in Figure 3 and in a preferred embodiment, the opening of pass-through aperture 122 disposed within top face 106, is arranged within recess 148 of body 140. As shown in Figure 5A and in a preferred embodiment, the opening of pass-through aperture 122 disposed within bottom face 108, is arranged with protruding portion 166 of body 140.

[0045] In a preferred embodiment, protruding portion 114 extends from front face 102 and recessed portion 116 is within rear face 104. When adjacent flue blocks, e.g., flue block 42 in Figure 2, abuts access flue block 100, a respective protruding portion of flue block 42 is arranged to be seated within recessed portion 116. The mating of a protruding portion and recessed portion of adjacently abutting flue blocks, greatly reduces potential leakage of heat, volatile gas, etc., through the seam created therebetween (i.e., similar to a “tongue and groove” connection between two components). Further, this mating configuration improves installation accuracy and efficiency — a notable improvement over mortaring two planar faces of abutting bricks and maintaining a level top surface between two abutting bricks.

[0046] Similar to the improvements described above and best shown in Figure 3, a preferred embodiment of access flue block 100 includes channel 126 (or groove) disposed within top face 106 proximate side face 110 and extending from front face 102 to rear face 104, and channel 128 (or groove) disposed within top face 106 proximate side face 112 and extending from front face 102 to rear face 104. As shown in Figure 5A, a preferred embodiment of access flue block 100 also includes protrusion 134 (or tongue) extending from bottom face 108 proximate side face 110 and extending from front face 102 to rear face 104, and protrusion 136 (or tongue) extending from bottom face 108 proximate side face 112 and extending from front face 102 to rear face 104. When another flue block, e.g., flue blocks 40-66 shown in Figures 1 and 2, is stacked on access flue block 100, protrusions or tongues, of the stacked flue block are seated within channels 126 and 128 (i.e., similar to a “tongue and groove” connection between two components). Similarly, one or more of the floor blocks or flue block 40, shown in Figures 1 and 2, may have channels or grooves that are arranged to accept protrusions 134 and 136. The mating of a channel or groove and protrusion or tongue of adjacently stacked flue blocks or a flue block and a floor block, greatly reduces potential leakage of heat, volatile gas, etc., through the seam created therebetween (i.e., similar to a “tongue and groove” connection between two components). Further, this mating configuration improves installation accuracy and efficiency — a notable improvement over mortaring two planar faces of vertically stacked bricks and maintaining a plumb stacking of the bricks.

[0047] In reference to Figure 4, access flue block 100 is differentiated from flue blocks 40- 66 shown in Figures 1 and 2 in that it has one or more access apertures. In some embodiments, access aperture 150 is disposed between side face 112 and inner wall 142 of flue aperture 120, such that access aperture 150 is in fluid connection with flue aperture 120 and respective openings of access aperture 150 are arranged in each of side face 112 and inner wall 142. In some embodiments, access aperture 152 is disposed between side face 110 and inner wall 144 of flue aperture 118, such that access aperture 152 is in fluid connection with flue aperture 118 and respective openings of access aperture 152 are arranged in each of side face 110 and inner wall 144. Access apertures 150 and 152 have inner walls 154 and 156, respectively. Both of inner walls 154 and 156 are tapered, described further, infra.

[0048] In reference to Figure 4, access aperture 150 is arranged to accept plug 158 therein and access aperture 152 is arranged to accept plug 160 therein. Plug 158 has outer surface 162 which has a tapered configuration in compliance with the taper of inner wall 154 of access aperture 150, allowing plug 158 to be inserted completely within access aperture 150 such that its outermost surface is flush with side face 110, as shown in Figure 3. Plug 160 has outersurface 164 which has a tapered configuration in compliance with the taper of inner wall 156 of access aperture 152, allowing plug 160 to be inserted completely within access aperture 152 such that its outermost surface is flush with side face 112. As such, plugs 158 and 160, access apertures 150 and 152, and side faces 110 and 112, preferably have a substantially identical thickness.

[0049] The tapered configuration of access apertures 150 and 152 is best shown in Figures 5B through 5E. In a preferred embodiment, access aperture 150 is generally defined by top wall 154a, bottom wall 154b, first tapered sidewall 154c, and second tapered sidewall 154d. Similarly, access aperture 152 is generally defined by top wall 156a, bottom wall 156b, first tapered sidewall 156c, and second tapered sidewall 156d. It should be appreciated that alternative tapered configurations are contemplated within the scope of the appending claims. Non-limiting examples may include one or more of having a tapered configuration to the top and bottom walls of the respective access apertures, where the sidewalls are substantially planar, or arranging the top and bottom walls to have a tapered configuration along with the tapered configuration of both sidewalls. As such, these alternatives may be applied to the plugs shown in Figure 4 to afford mating compliance within the respective access apertures.

[0050] In reference to Figures 5D and 5E, access aperture 150 has a pair of openings, internal opening 150a disposed within internal wall 142 of flue aperture 120 and external opening 150b disposed within side face 112, and similarly, access aperture 152 has a pair of openings, internal opening 152a disposed within internal wall 144 of flue aperture 118 and external opening 152b disposed within side face 110. Preferably, external openings 150b and 152b are larger than internal openings 150a and 152a, respectively. As such, there is angle a formed between opposite external edges of the external openings and a respective tapered sidewall, where angle a is preferably acute, and more specifically, in a non-limiting manner, within the approximate range of 5°-30°.

[0051] Figures 6A through 6C illustrate an embodiment of the plugs that are inserted into the access apertures. Plug 158 is shown, however, it should be appreciated that the following description also applies to plug 160. In possible embodiment, plug 158 comprises a tapered outer surface 164 which is arranged between outer face 174 and inner face 176, where outer surface 164 may comprise top face 170, bottom face 172, first tapered side face 178, and second tapered side face 180. Outer face 174 is larger than inner face 176, where inner face 176 is arranged to be seated within one of the internal openings of one of the access apertures of the flue block. See Figures 3, 4, and 5A through 5E. As such, there is angle P formed between opposite external edges of the outer face and the respective tapered side faces, where angleis preferably acute, and more specifically, in a non-limiting manner, within the approximate range of 5°-30°. Thus, in some embodiments, angle a is substantially equal to angle p.

[0052] In reference to Figures 3 through 6C, the tapered configurations of both access apertures 150 and 152 and plugs 158 and 160, respectively, allow plugs 158 and 160 to be removed from their respective access apertures once plugs 158 and 160 are mortared in placed. If the access apertures and the plugs did not have a tapered configuration, removal, in order to access flue apertures 118 and 120 (or the entirety of flues 36 and 38 of heating wall 34, as shown in Figures 1 and 2), would require additional tools and material removal around the access apertures to remove the plugs.

[0053] This is advantageous for a few reasons, first, as the tiers of a heat wall are built upwardly in the vertical direction, excess mortar, which secures both stacked and abutting blocks, falls downwardly in the flues of the heating wall and gathers in the bottommost tier, which can cause issues when combustion occurs within the heating wall. Second, if tools or other items fall into the flue during installation, they can be easily removed from at least one of the access apertures before the plugs are installed into the access aperture. Third, the access apertures provide a location for operators to inspect the inside of the flues of the heating wall.

[0054] Adverting to Figure 7 and with reference to Figures 1 and 2, Figure 7 generally depicts a possible alternative embodiment of access flue block 100. In some embodiments, flue block 100 may include pass-through riser 182, generally illustrated as a plurality of stacked blocks in Figures 1 and 2. As shown, pass-through riser 182 is an extension of a conduit body that houses pass-through aperture, e.g., body 138 extends in a vertical direction from top face 106. Pass-through riser 182 may be configured as an integrated piece of flue block 100, eliminating the need for additional blocks to build pass-through riser in the vertical direction, thereby eliminating additional seams and reducing the potential for leakage through those seams. Thusly, if access flue block 100 having pass-through riser 182 is incorporated into a heating wall, the flue blocks that are stacked thereon, will not need additional components and / or blocks to continually build the vertical height of a pass-through riser in the ascending tiers of the heating wall.

[0055] In reference to Figures 1-4 and 8, it should be appreciated that in some embodiments and in accordance with the technology, flue block 40 (and flue blocks 42 through 66) may include all of the components of access flue block 100, but for access apertures 150 and 152. In other embodiments of flue blocks 40 through 66, bodies 138 and 140 (and the passageways therein, e.g., pass-through apertures 122 and 124) are optional components, as generally shown in TIERS 5-8 in Figure 2, and additional tiers thereabove in vertical direction VD1, allowingselectability of the particular tier within a heating wall where gases and air mix, i.e., where a pass-through riser terminates within a flue.

[0056] Thus, Figure 8 generally illustrates a preferred method of stacking one or more flue blocks to build heating wall and a heating wall for a coke oven, specifically illustrating how access flue block 100 is stacked onto a pair of abutting flue blocks, e.g., flue blocks 40, and generally centered in relation to the seam created between the pair of abutting flue blocks. As described supra, protruding components (of a flue block being stacked on one or more flue blocks) are at least partially seated in recessed components of the lower flue block, e.g., a protruding section of a front face is seated within a recessed section of a rear face, a tongue extending from a bottom face is seated within a groove disposed within a lower face, etc. These interactions can be generally described as a “mating” of one or more components of at least two flue blocks, either arranged within the same tier along longitudinal directions LD1 and LD2, stacked in two tiers in vertical directions VD1 and VD2, or a combination thereof. The mating, as generally depicted, prevents blocks in a lower tier, e.g., TIER 1, and the next adjacent tier, e.g., TIER 2, from moving or being displaced in longitudinal directions LD1 and LD2 and transverse directions TD1 and TD2. Thus, the mating of flue block 100 with flue blocks 40 it is stacked on top of, maintains an abutted configuration of flue blocks 40 thereunder.

[0057] Thus, in reference to all of the drawings, heating wall 34 for coke oven 10 may comprise plurality of flue blocks 40-66 and 100, forming wall with a plurality of tiers, each tier defined by one or more flue blocks of plurality of flue blocks 40-66, and 100, stacked in vertical direction VD1, one or more passageways, e.g., flues 36 and 38, within the wall formed by one or more passageways, e.g., flue apertures 118 and 120, within each of plurality of flue blocks 40-66, and 100, and one or more access ports, e.g., access apertures 150 and 152, in communication with the one or more passageways, e.g., flue apertures 118 and 120, of at least one flue block, e.g., access flue block 100, of the stacked plurality of flue blocks 40-66, and 100, wherein each of the one or more access ports, e.g., access apertures 150 and 152, are adapted to accept a plug, e.g., plugs 158 and 160, therein. In some embodiments, each tier of the plurality of tiers, e.g., TIER 1, comprises one or more flue blocks, e.g., flue blocks 40, of the plurality of flue blocks abutting an adjacent flue block, e.g., flue blocks 40 are mated.

[0058] One having skill in the art and in accordance with the technology, will appreciate that the characteristic of “abutting” and “stacked,” when referencing one or more flue blocks in a heating wall, is intended to account for mortar, or other viable means or materials known in the art or hereinafter developed, that may be present within a seam created by adjacentlystacked or abutted flue blocks. It should be further appreciated that the term “seam” should be considered substantially synonymous with the term “joint”.

[0059] It will be appreciated that the features of the various embodiments described and / or illustrated herein may be combined in different ways, provided such combinations are technically compatible. Unless expressly indicated otherwise, any feature described in connection with a particular embodiment may be used alone or in combination with other features disclosed herein. Accordingly, the scope of the invention encompasses not only the embodiments explicitly described and / or illustrated, but also any variations, modifications, and combinations thereof that fall within the contribution disclosed, such that the claims are clear, concise, and supported by the description. Thus, various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art are also intended to be encompassed by the claims.REFERENCE NUMERALS

[0060] 10 Coke oven; 12 Oven; 14 Regenerator; 16 Pier block or pillar block; 18 Corbel;20 Corbel block; 22 Corbel block; 24 Gunblock; 26 Floor; 28 Floor block; 30 Floor block; 32 Floor block; 34 Heating wall; 36 Flue; 38 Flue; 40-66 Flue block; 68 Pass-through riser; 70 Pass-through riser; 72 passageway; 74 Aperture; 76 Aperture; 78 aperture; 80 aperture.

[0061] 100 Access flue block; 102 Front face; 104 Rear face; 106 Top face; 108 Bottom face; 110 Side face; 112 Side face; 114 Protruding portion; 116 Recessed portion; 118 Flue aperture; 120 Flue aperture; 122 Pass-through aperture; 124 Pass-through aperture; 126 Channel or groove; 128 Channel or groove; 130 Lip; 132 Lip; 134 Protrusion or tongue; 136 Protrusion or tongue; 138 Body; 140 Body; 142 Inner wall; 144 Inner wall; 146 Recess; 148 Recess; 150 Access aperture; 150a Internal opening; 150b External opening; 152 Access aperture; 152a Internal opening; 152b External opening; 154 Inner wall; 154a Top inner wall; 154b Bottom inner wall; 154c First tapered sidewall; 154d Second tapered sidewall; 156 Inner wall; 156a Top inner wall; 156b Bottom inner wall; 156c First tapered sidewall; 156d Second tapered sidewall; 158 Plug; 160 Plug; 162 Outer surface; 164 Outer surface; 166 Protruding portion; 168 Protruding portion; 170 Top face; 172 Bottom face; 174 Outer face; 176 Inner face; 178 Tapered side face; 180 Tapered side face; 182 Pass-through riser; a Angle; Angle.

[0062] LD1 Longitudinal direction; LD2 Longitudinal direction; TD1 Transverse direction; TD2 Transverse direction; VD1 Vertical direction; VD2 Vertical direction.

Claims

AMENDED CLAIMS received by the International Bureau on 25 February 2026 (25.02.2026)What Is Claimed Is:

1. A flue block for a heating wall of a coke oven, comprising: a top face, a bottom face, a first side face, a second side face, a first end, and a second end; a first passageway disposed between the top and bottom faces having respective openings within the top and bottom faces; a second passageway disposed between the top and bottom faces having respective openings within the top and bottom faces; a first conduit disposed within the first passageway and having a third passageway therein, the third passageway having respective openings within the top and bottom faces; a second conduit disposed within the second passageway and having a fourth passageway therein, the fourth passageway having respective openings within the top and bottom faces; a first access port disposed within one of side faces and in communication with the first passageway, thereby forming a fifth passageway; and, a second access port disposed within one of side faces and in communication with the second passageway, thereby forming a sixth passageway, wherein each of the access ports are arranged to accept a plug therein.

2. The flue block for a heating wall of a coke oven recited in claim 1 , wherein said first end comprises a protruding portion extending therefrom and said second end comprising a recessed portion arranged therein.

3. The flue block for a heating wall of a coke oven recited in claim 1 or 2 further comprising: a first groove and a second groove disposed within the top face, each groove being proximate one of the sidewalls and extending from the first end to the second end; a first protrusion and a second protrusion extending from the bottom face, each protrusion being proximate one of the sidewalls and extending from the first end to the second end.

4. The flue block for a heating wall of a coke oven recited in claim 1 or 2 further comprising: a first plug adapted to be inserted into the first access port; and, a second plug adapted to be inserted into the second access port.

5. The flue block for a heating wall of a coke oven recited in claim 1 or 2, wherein the fifth passageway is tapered and the sixth passageway is tapered.

6. The flue block for a heating wall of a coke oven recited in claim 1 or 2, wherein: the first conduit includes a recessed portion disposed within the top face and the second conduit includes a recessed portion disposed within the top face; and, the first conduit includes a protruding portion extending from the bottom face and the second conduit includes a protruding portion extending from the bottom face.

7. The flue block for a heating wall of a coke oven recited in claim 3 further comprising: a first plug adapted to be inserted into the first access port, the first plug being tapered such that it can be seated within the first access port; and, a second plug adapted to be inserted into the second access port, the second plug being tapered such that it can be seated within the first access port.

8. The flue block for a heating wall of a coke oven recited in claim 1 or 2 further comprising a pass-through riser extending from one or more of the first conduit or the second conduit.

9. A heating wall for a coke oven, comprising: a plurality of flue blocks forming a wall with a plurality of tiers, each tier defined by one or more flue block of the plurality of flue blocks stacked in a vertical direction; one or more passageways within the wall formed by one or more passageways within each of the flue blocks; and, one or more access ports in communication with the one or more passageways of at least one flue block of the stacked plurality of flue blocks, wherein each of the one or more access ports are adapted to accept a plug therein.

10. The heating wall for a coke oven recited in claim 9, wherein each tier of the plurality of tiers comprises one or more flue blocks of the plurality of flue blocks abutting an adjacent flue block.

11. The heating wall for a coke oven recited in claim 9 or 10, wherein the one or more access ports are arranged within at least one flue block of the plurality of flue blocks of one or more of a bottommost tier of the plurality of tiers or stacked directly above the bottommost tier of the plurality of tiers.

12. The heating wall for a coke oven recited in claim 9 or 10, wherein each of the one or more access ports are adapted to accept a plug therein.

13. The heating wall for a coke oven recited in claim 9 or 10 further comprising one or more plugs adapted to be inserted into the one or more access ports.

14. The heating wall for a coke oven recited in claim 9 or 10, wherein each of the one or more access ports are tapered.

15. The heating wall for a coke oven recited in claim 9 or 10, wherein the one or more access ports are arranged within an access flue block of the plurality of flue blocks, wherein the access flue block comprises: a first passageway disposed between a top face and a bottom face, the first passageway having respective openings within the top and bottom faces; a second passageway disposed between the top and bottom faces having respective openings within the top and bottom faces; a first conduit disposed within the first passageway and having a third passageway therein, the third passageway having respective openings within the top and bottom faces; a second conduit disposed within the second passageway and having a fourth passageway therein, the fourth passageway having respective openings within the top and bottom faces; a first access port disposed within one of side faces and in communication with the first passageway, thereby forming a fifth passageway; and, a second access port disposed within one of side faces and in communication with the second passageway, thereby forming a sixth passageway, wherein each of the access ports are arranged to accept a plug therein.

16. A flue block for a heating wall of a coke oven, comprising: a first passageway disposed between a top face and a bottom face, the first passageway having respective openings within the top and bottom faces; a second passageway disposed between the top and bottom faces having respective openings within the top and bottom faces; one or more access ports disposed within one of a pair of side faces and in communication with one or more of the first passageway or the second passageway, thereby forming one or more access passageways; and, wherein each of the one or more access passageways are arranged to accept a plug therein.

17. The flue block for a heating wall of a coke oven recited in claim 16, wherein: each of the one or more access passageways is tapered; and, each of the one or more plugs are tapered.

18. The flue block for a heating wall of a coke oven recited in claims 16 or 17 further comprising: a first access port disposed within one of the pair of side faces and in communication with the first passageway, thereby forming a first access passageway; and, a second access port disposed within the other of the pair of side faces and in communication with the second passageway, thereby forming a second access passageway.

19. The flue block for a heating wall of a coke oven recited in claim 18, wherein: the first access passageway is tapered; and, the second access passageway is tapered.

20. The flue block for a heating wall of a coke oven recited in claim 19 further comprising: a first plug adapted to be inserted into the first access passageway, the first plug being tapered in relation to the taper of the first access passageway such that it may be seated therein; and, a second plug adapted to be inserted into the second access passageway, the second plug being tapered in relation to the taper of the second access passageway such that it may be seated therein.

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