Fired Precast Block with Uneven Side Surfaces for Blast Furnace Runners
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Solution Overview
Problem
Blast furnace runners face severe wear and corrosion at specific portions due to high-temperature molten metal and slag, leading to early degradation of refractory blocks and increased production costs, with existing solutions not fully addressing the issue of block drop-off and uniform wear.
Innovation Solution
A fired precast block with a unique design featuring a planar and uneven surface, including groove-shaped concave portions on opposing side surfaces, is embedded in a castable to prevent drop-off and enhance thermal resistance, allowing it to grasp the remaining wear lining and maintain position despite wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precast refractory blocks are combined and placed to protect vulnerable portions, then wear resistance at critical areas is improved, but the complexity of using multiple block shapes increases and production costs rise
Solution Approach 1:
The invention applies local quality by creating an uneven surface structure (with protrusions and recesses) specifically on the side surfaces of the precast blocks that are in contact with the castable. This localized structural modification allows the blocks to interlock with the surrounding castable material, providing enhanced wear resistance at critical areas without requiring multiple different block shapes. The solution addresses the wear resistance need while avoiding the complexity of producing and managing various block geometries.
2Reliability
If precast refractory blocks are combined and placed, then protection against molten metal and slag is improved, but early drop-off of blocks occurs due to wear of surrounding material
Solution Approach 1:
The invention applies preliminary action by pre-forming the uneven surface structure (protrusions and recesses) on the precast blocks before installation. This preliminary structural preparation ensures that when the blocks are placed and the castable is applied, the blocks are immediately equipped with interlocking features that prevent drop-off. The uneven surface is created in advance during block manufacturing, so that when installed, the blocks automatically grasp the surrounding castable and resist early wear and drop-off, extending service life.
3Ease of manufacture
If uniform wear lining is used throughout, then manufacturing simplicity is maintained, but severe local wear at slag line and metal line portions occurs
Solution Approach 1:
The invention applies local quality by equipping precast blocks with specific uneven surface structures (protrusions and recesses) on their side surfaces that will contact the castable. This localized structural feature provides enhanced mechanical interlocking and wear resistance precisely where needed—at the interfaces between blocks and the surrounding castable material—without requiring the entire wear lining to be manufactured differently. The solution maintains overall manufacturing simplicity while providing targeted protection at critical wear locations.
Data Source
AI summary
A fired precast block prevents itself from dropping off early due to corrosion and increases service life of a blast furnace runner, etc. when used in a very vulnerable portion of the blast furnace runner, etc., and can be produced at low costs. The fired precast block has an upper surface to contact molten metal or slag, a lower surface opposing the upper surface, and a plurality of side surface. The fired precast block is used by being embedded in a castable in such a manner that the upper surface is exposed from the castable and the lower surface and the plurality of side surfaces contact the castable. Each side surface of at least one opposing pair of side surfaces includes a planar portion and an uneven portion. The uneven portion has at least one groove-shaped concave portion.