Glass Furnace Refractory Hoist Beam Assembly for Block Placement
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Solution Overview
Problem
The construction of glass furnace refractory structures, such as regenerators, is labor-intensive and prone to joint degradation due to corrosive gases, leading to structural weakness and increased downtime, while large refractory blocks are difficult to install and replace components like checker bricks efficiently.
Innovation Solution
A method and apparatus using header support beam assemblies with angulated C-shaped beams and hanger assemblies to facilitate the hoisting and placement of refractory components, including refractory wall blocks and checker bricks, utilizing a moveable hoist system supported by these beams to construct or reconstruct refractory structures efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If refractory structures are constructed using individual bricks with mortar, then the structure can be built with standard materials, but the joints are weak and susceptible to degradation by corrosive gases
Solution Approach 1:
The refractory structure is divided into modular components: precast refractory blocks with integrated reinforcement and separate checker bricks. This segmentation allows each component to be manufactured independently with high quality, then assembled together, reducing joint degradation while maintaining construction feasibility
Solution Approach 2:
The refractory blocks combine multiple materials: refractory concrete, reinforcement bars, and mortar joints in a composite structure. This composite approach creates stronger, more durable blocks that resist corrosive gas attack better than traditional brick-and-mortar construction
2Reliability
If large refractory blocks are fabricated by pressing, molding or casting, then fewer joints are needed and structure life is prolonged, but installation during construction of large-scale structures becomes problematic
Solution Approach 1:
Large refractory structures are segmented into manageable precast blocks of standardized sizes. These blocks can be fabricated using pressing, molding, or casting methods to minimize joints, then systematically installed during construction. The segmentation makes installation feasible while maintaining the benefits of reduced joint count
Solution Approach 2:
The refractory blocks are pre-fabricated and pre-positioned before final assembly. This preliminary action allows the blocks to be prepared in advance with proper curing and quality control, then installed more efficiently during construction, overcoming the installation difficulties of large-scale structures
3Productivity
If checker bricks are replaced near or at the end of their useful life, then optimal production efficiencies are maintained, but replacement is currently difficult to perform
Solution Approach 1:
The regenerator structure is segmented into replaceable modules with checker bricks that can be independently accessed and replaced. This modular segmentation allows targeted replacement of worn components without shutting down the entire furnace, maintaining production efficiency while simplifying the replacement process
Solution Approach 2:
The system allows dynamic replacement of checker bricks during operational cycles. The modular design enables bricks to be replaced when needed without fixed timing constraints, allowing maintenance to be performed dynamically based on actual wear conditions rather than following a rigid replacement schedule
4Manufacturing precision
If the construction process is made more labor intensive, then precise placement of refractory components can be achieved, but construction time increases to many weeks
Solution Approach 1:
Refractory components are pre-positioned and pre-aligned during fabrication, and assembly guides are pre-installed on the structure. This preliminary action establishes precise placement references before the actual construction begins, enabling accurate component placement while reducing overall construction time by eliminating time-consuming alignment operations
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
Facilitates the efficient installation and replacement of refractory components, reducing joint degradation and prolonging the life of refractory structures by minimizing labor-intensive construction and maintenance, thereby enhancing operational efficiency and reducing downtime.
Implementation Method 1
hanger assemblies (56) that dependently support the rail assemblies (60, 62) to the header beam members (52a, 52b) so as to allow the rail assemblies (60, 62) to be moved reciprocally along a spanwise extent of the header beam members (52a, 52b)
Implementation Method 2
A moveable hoist supporting assembly supported by the header support beam assembly and moveable between the opposed pairs of side and end walls
Data Source
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AI summary
Methods and apparatus for constructing or reconstructing 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. A header support beam assembly is provided so as to extend at an angle between respective pairs of side wall buckstays. A moveable hoist moveable hoist supporting assembly supported by the header support beam assembly and moveable between the opposed pairs of side and end walls. In such a manner, refractory components, e.g., refractory wall blocks and/or checker bricks, may be hoisted into position when constructing or reconstructing the refractory structure.