Refractory Anchor Device with Semi-Hexagonal Cells
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Solution Overview
Problem
Existing refractory anchoring systems for high-temperature vessels, such as HEXMESH, are prone to 'biscuiting' due to thermal expansion and contraction, leading to premature failure and the need for costly replacements. Additionally, these systems are time-consuming and cumbersome to install due to the requirement for numerous welds and custom fitting.
Innovation Solution
The development of refractory anchoring devices with unenclosed semi-hexagonal cell openings, which include a main body shaped like two end-to-end Y's and mounting features for secure attachment to the vessel. These devices form substantially hexagonal cells when arranged together, providing flow passageways for refractory interlinking and reducing the likelihood of biscuiting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If HEXMESH anchor sheets are welded flush with and rigidly to the vessel shell, then strong attachment to the vessel shell is achieved, but the system becomes prone to biscuiting when the vessel shell experiences thermal expansion or contraction
Solution Approach 1:
The continuous hex mesh is divided into discrete anchor elements spaced apart from each other. Each anchor element independently attaches to the vessel shell, allowing local thermal movement without transmitting stress across the entire mesh structure, thereby preventing biscuiting while maintaining attachment strength.
Solution Approach 2:
The rigid flush-welded connection is replaced with a spaced-apart configuration where anchors can move independently relative to each other and to the vessel shell. This dynamic arrangement allows the anchors to accommodate thermal expansion and contraction without compromising the refractory lining integrity.
2Adaptability or versatility
If hex sheets are cut on-site to custom-fit each vessel and beat into shape with a hammer, then custom fitting to the vessel shape is achieved, but the installation process becomes very time-consuming and tedious
Solution Approach 1:
The system uses discrete, pre-formed anchor elements rather than continuous sheets that must be cut and shaped. Each anchor can be independently positioned and attached to the vessel shell, eliminating the time-consuming processes of on-site cutting, beating, and shaping while maintaining the ability to custom-fit to various vessel geometries.
Solution Approach 2:
The anchor elements are pre-formed and prepared before installation, eliminating the need for on-site cutting and shaping operations. This preliminary preparation significantly reduces installation time while still allowing adaptation to different vessel shapes through strategic placement of the discrete anchors.
3Strength
If a large number of welds are required to attach hex sheets to the vessel shell, then strong attachment is achieved, but the installation process becomes cumbersome and time-consuming
Solution Approach 1:
The continuous weld pattern required for hex mesh is replaced with discrete welds at individual anchor locations. This segmentation reduces the total number of welds significantly while maintaining adequate attachment strength through properly positioned and sized welds at each anchor point.
Solution Approach 2:
The complex continuous welding process is extracted and replaced with simple discrete welds at specific anchor locations. This extraction eliminates the need for extensive welding while maintaining the essential attachment function, thereby simplifying the installation process.
Data Source
AI summary
Refractory anchoring devices include a main body and a mounting feature for mounting to a thermal vessel. The main body has the shape of two end-to-end Y's forming a central segment, branch segments extending from ends of the central segment, and extension segments extending from the branch segments, to collectively form four unenclosed cell openings that are semi-hexagonally shaped. Some embodiments include reinforcement segments extending into respective cell openings, voids extending through respective adjacent branch and extension segments, an underbody gap under the central segment, a single stud-welding stud for the mounting feature, and/or a collar-and-stud connection between the anchor main body and a stud-welding stud of the mounting feature. Refractory anchoring systems and methods include an array of the refractory anchoring devices arranged and mounted so that the unenclosed semi-hexagonal cell openings of adjacent anchoring devices cooperatively form substantially hexagonal cells.