Refractory Block Installation with Overhead Crane and Buck Stays
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Solution Overview
Problem
The current methods for constructing and maintaining refractory structures in glass furnaces are labor-intensive, prone to joint degradation, and require frequent replacement of components, leading to inefficiencies and downtime due to the use of small refractory bricks and complex installation processes.
Innovation Solution
The use of an overhead crane apparatus and large pre-cast refractory blocks with external buck stays to construct and maintain regenerator structures, allowing for efficient installation and replacement of refractory components, reducing the number of joints and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If small refractory bricks are used to construct regenerator structures, then the structures can be built with available materials and methods, but the number of joints increases leading to faster degradation and more frequent rebuilding
Solution Approach 1:
The regenerator structure is segmented into large modular refractory blocks that can be handled and installed as complete units. Each block contains internal segmentation for the checker pattern, eliminating the need for numerous external joints between small bricks. This reduces joint degradation while maintaining the functional segmentation needed for heat exchange.
Solution Approach 2:
Multiple small refractory bricks that would form the checker pattern are merged into single large pre-cast refractory blocks. The checker pattern is formed internally within each block during manufacturing, combining what would otherwise require thousands of individual brick placements into manageable units with minimal external joints.
2Reliability
If large pre-cast refractory blocks are used to reduce joints, then structure lifespan is improved, but installation becomes more difficult during construction
Solution Approach 1:
The overhead crane apparatus provides counterbalancing and lifting capability to handle the weight of large pre-cast refractory blocks. The crane system with movable pulley and cable arrangement distributes the lifting load, making it feasible to install blocks that would be too heavy for manual handling or simple hoisting equipment.
Solution Approach 2:
The overhead crane apparatus serves as an intermediary mechanism between the ground-level construction area and the elevated installation position. It mediates the transfer of large refractory blocks from ground storage to the regenerator structure location, enabling installation without requiring workers to manually lift and position heavy blocks.
3Productivity
If components are replaced near the end of useful life to maintain efficiency, then production efficiency is optimized, but downtime increases due to difficult replacement processes
Solution Approach 1:
The regenerator structure is designed with segmented large blocks that can be individually removed and replaced. The overhead crane apparatus enables these large segments to be lifted out and new ones installed without requiring disassembly of the entire structure, significantly reducing replacement time compared to working with individual small bricks.
Solution Approach 2:
Refractory blocks are pre-cast off-site with the complete checker pattern already formed, allowing for preliminary preparation of replacement components. This eliminates the time-consuming on-site construction process and allows blocks to be ready for immediate installation when replacement is needed, minimizing downtime.
4Ease of manufacture
If hundreds of thousands of refractory bricks are individually placed with mortar, then the structure can be built, but labor intensity increases and construction time extends to many weeks
Solution Approach 1:
The manufacturing process merges the formation of multiple refractory bricks into a single pre-cast block. The checker pattern that would require thousands of individual brick placements is formed internally within each large block during the pre-casting process, dramatically reducing the number of installation operations required.
Solution Approach 2:
The complex checker pattern geometry is copied into the internal structure of each large refractory block during manufacturing. This allows the intricate heat exchange geometry to be replicated without requiring manual placement of individual bricks, as the pattern is already formed in the pre-cast block.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables faster and more efficient construction and maintenance of refractory structures, prolonging their lifespan and reducing the need for frequent replacements, thereby improving thermal efficiency and operational reliability of glass furnaces.
Implementation Method 1
an overhead crane apparatus having a hoist for hoisting the large pre-cast refractory blocks into position
Implementation Method 2
at least one pair of buck stays positioned outside the refractory blocks and in compression against the refractory blocks
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
Methods and apparatus for constructing refractory structures, e.g., glass furnace regenerator structures and/or glass furnace structures having walls formed of refractory block and buck stays externally supporting the walls are provided. Opposed pairs of supports are connected to at least a respective one of the vertically oriented buck stays with cross-support beams spanning the refractory structure between a respective pair of the supports. An overhead crane assembly is supported by the cross-support beams. In such a manner, refractory components of the refractory structure (e.g., refractory wall blocks and/or refractory checker bricks) may be installed using the overhead crane assembly.