Fiber-Reinforced Silica Modules for Low-Joint Coke Oven Masonry
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Solution Overview
Problem
Existing refractory bricks for coke ovens face issues with large mortar joint areas, high-temperature corrosion, limited structural strength, slow masonry, and lengthy baking times, which affect their durability and efficiency.
Innovation Solution
A fiber-reinforced silicious material is produced using a modular pouring integrated molding process, incorporating explosion-proof fibers and optimized raw material ratios, allowing for prefabricated modules that can be easily assembled, reducing mortar joints and accelerating construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ordinary silica bricks with compression molding technology are used, then the manufacturing process is simple, but the mortar joint area increases and structural strength decreases
Solution Approach 1:
The patent merges multiple bricks into a large integrated module (e.g., one module replaces at least 100 ordinary silica bricks), eliminating the need for numerous mortar joints while maintaining manufacturing feasibility through mold pouring technology
Solution Approach 2:
The patent segments the coke oven wall into modular units that can be pre-fabricated and assembled, allowing each module to be manufactured independently while achieving overall structural integrity when installed
2Area of stationary object
If the size of silica bricks is enlarged to reduce mortar joint area, then the number of joints decreases, but cracking during firing and dimensional control become problematic
Solution Approach 1:
The patent changes the manufacturing parameters by using mold pouring instead of compression molding, enabling precise control of large module dimensions and internal structure without the cracking issues that plague enlarged compressed bricks
3Ease of manufacture
If traditional silica brick masonry is used, then the construction method is conventional, but the masonry period is long and labor costs increase
Solution Approach 1:
The patent applies preliminary action by pre-fabricating large modules off-site with all internal structures and reinforcements already in place, so that on-site installation requires only placing and securing the modules, reducing masonry time by more than half
4Device complexity
If ordinary silica bricks are used, then the material is simple, but high-temperature corrosion resistance is insufficient
Solution Approach 1:
The patent uses composite materials combining silicious materials with high-temperature resistant fibers and additives, creating a material that maintains simplicity in application while achieving superior corrosion resistance through compositional complexity
Data Source
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AI summary
Provided is a fiber-reinforced silicious module, and the preparation of raw materials thereof includes the following raw materials in parts by mass: 82-92 parts of quartz aggregate, 1-2 parts of refractory cement and 7-15 parts of zirconium-containing silicon dioxide micropowder. The module greatly reduces ash joints in the construction of silica bricks for a coke oven, improves a volume stability, a thermal shock property and an impact resistance, prolongs the service life of the coke oven, changes an oven building way, quickly dries the oven and improves the maintenance efficiency, and the strength and high-temperature corrosion resistance of the module can also be improved while preventing cracking.