Coke Oven Corbel Structures for Modular Refractory Construction
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Solution Overview
Problem
Coke ovens with traditional refractory brick structures face high costs and downtime issues due to complex designs and the need for multiple types of bricks, which are costly and difficult to handle and install, especially large ceramic bricks that require specialized lifting and have longer heat-up times.
Innovation Solution
The corbel structures are formed by assembling multiple stacked tiers of refractory blocks with specifically designed saddle blocks, central diagonal flue blocks, Z-shaped, T-shaped, and spacer blocks that create vertically and diagonally oriented flues, allowing for efficient gas flow and heat distribution, reducing the need for multiple brick types and simplifying construction and repair processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional refractory brick structures are used with multiple types of bricks to achieve complex flue designs and proper heat distribution, then the functional requirements of the coke oven are met, but the construction cost increases and construction time extends
Solution Approach 1:
The corbel structure is divided into multiple tiers (first tier, second tier, third tier, fourth tier) with each tier containing specific types of blocks (saddle blocks, central diagonal flue blocks, spacer blocks, etc.). This segmentation allows for standardized modular construction while achieving complex flue patterns, reducing overall construction time compared to traditional brick-by-brick assembly.
Solution Approach 2:
The refractory blocks are designed with multi-functional features: saddle blocks provide both structural support and define flue passages, central diagonal flue blocks create both structural integrity and gas flow paths, and spacer blocks maintain both dimensional accuracy and flue spacing. This multi-functionality reduces the number of different block types needed compared to traditional brick construction.
2Device complexity
If large ceramic bricks are used to reduce the number of brick types, then construction complexity decreases, but handling difficulty increases requiring specialized mechanical lifting devices
Solution Approach 1:
Instead of using excessively large bricks that would be difficult to handle, the structure is segmented into multiple manageable tiers with standardized block sizes. Each tier uses the same set of block types (saddle blocks, central diagonal flue blocks, spacer blocks), reducing the overall number of unique brick types while keeping individual blocks at a manageable size for handling.
Solution Approach 2:
The block dimensions are optimized to balance structural requirements with handling feasibility. The blocks are large enough to reduce the total number of pieces needed but small enough to be maneuvered without specialized lifting equipment, achieving an optimal parameter range for both construction efficiency and ease of operation.
3Quantity of substance
If conventional silica bricks are used instead of fused silica bricks to reduce cost, then material cost decreases, but heat-up time increases many times
Solution Approach 1:
The patent specifies the use of fused silica bricks rather than conventional silica bricks, maintaining the critical material property (fused silica content) that enables rapid heat-up. This parameter choice prioritizes operational efficiency (heat-up time) over material cost, recognizing that the performance benefit outweighs the additional expense in coke oven operations.
4Ease of manufacture
If specialized mechanical lifting devices are used to handle large bricks, then construction capability improves, but equipment cost and complexity increase
Solution Approach 1:
The corbel structure is segmented into multiple tiers with standardized block sizes that can be handled with conventional lifting equipment. This segmentation eliminates the need for specialized mechanical lifting devices while maintaining construction capability, as each block is sized appropriately for standard handling equipment.
Data Source
AI summary
Coke oven corbel structures include an assembly of multiple stacked tiers of refractory blocks defining a plurality of substantially vertically oriented central flues and a plurality of diagonally oriented lateral flues. At least one tier of refractory blocks in the assembly includes by an alternating plurality of saddle blocks and central diagonal flue blocks. The saddle blocks may include a laterally opposed pair of upright columns which define therebetween a rectangular channel, and a substantially vertically oriented cylindrical flue extending from a bottom surface of the saddle blocks to the rectangular channel thereof. The central diagonal flue blocks may include an arcuately concave flue channel defined between top and bottom surfaces thereof so that an upper opening to the flue channel at the top surface is inwardly offset relative to a lower opening thereof at the bottom surface.