Precast Refractory Block Anchoring for Furnace Repair

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Solution Overview

Problem

Current refractory surfaces in metallurgical vessels, such as reheat furnaces, face challenges with thermal stress, physical stress, and abrasion, leading to frequent repairs that are either costly or time-consuming, particularly when using shotcrete or rebricking methods, which do not provide long-lasting solutions.

Innovation Solution

A precast refractory block with adjustable positioning and support mechanisms allows for precise installation and anchoring within existing refractory structures, using a recess or form walls technique to ensure proper alignment and filling with mortar, providing enhanced durability against thermal and mechanical stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If shotcrete or rebricking methods are used to repair refractory surfaces, then repair can be performed, but the repairs are costly and time-consuming with limited durability

Engineering Contradiction:

Improvedurability of refractory repairVSAvoidtime required for repair

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The refractory blocks are precast off-site with precise dimensions and integrated anchoring features before installation. This preliminary preparation eliminates the need for time-consuming on-site mixing and casting operations, while ensuring consistent quality and durability of the repair components.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The refractory repair system is divided into modular precast blocks that can be individually manufactured, transported, and installed. This segmentation allows for standardized production with built-in anchoring mechanisms, enabling quick replacement of damaged sections without requiring extensive repair operations.

Inventive Principle:

Principle #1Segmentation

2Duration of action of stationary object

If traditional refractory repair methods are used, then repair is possible, but frequent repairs are needed due to thermal and mechanical stress

Engineering Contradiction:

Improvelifespan of refractory surfaceVSAvoidcomplexity of repair process

Core Design Contradiction:

Duration of action of stationary objectVSEase of manufacture

Solution Approach 1:

The precast refractory blocks incorporate composite material structures with integrated metal anchoring features embedded within the refractory matrix. This composite construction provides enhanced mechanical strength and thermal resistance, enabling the blocks to withstand thermal cycling and mechanical stress without spalling or detachment, thereby extending service life.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The precast blocks include self-contained anchoring systems with integrated features such as recesses, protrusions, or embedded metal elements that automatically engage with corresponding features in the existing refractory structure during installation. This self-service design ensures proper positioning and secure attachment without requiring complex external fixing mechanisms.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If precast refractory blocks with anchoring mechanisms are used, then installation precision and durability are improved, but the device complexity increases

Engineering Contradiction:

Improveinstallation precision of refractory blocksVSAvoidcomplexity of anchoring mechanism

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The anchoring features are localized to specific areas of the precast blocks rather than being distributed throughout the entire structure. For example, recesses or protrusions are positioned only at the contact surfaces where engagement with the existing refractory is needed, while the bulk of the block maintains simple homogeneous refractory material properties.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The anchoring mechanism uses simple geometric intermediaries such as recesses, protrusions, or embedded metal pins that facilitate engagement between the precast block and the existing refractory structure. These intermediary features provide precise positioning and secure attachment through basic mechanical interlocking rather than complex fastening systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10890380B2Precast replacement surfaces for contact with heated metal

Publication Date: 2021.01.12 VESUVIUS USA CORP

AI summary

A replacement product for a portion of a castable refractory surface contains a precast refractory piece with accommodation for an adjustable positioning structure for conforming the working surface of the precast refractory piece to the castable refractory surface. A process for installing the precast refractory piece includes positioning the precast refractory piece with respect to the castable refractory surface, and introducing castable material into an interface volume between the precast refractory piece and the castable refractory surface.