Segmented Refractory Rider Arch for Coke Ovens
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The construction and repair of massive refractory structures, such as coke ovens and glass furnaces, are time-consuming and costly due to the need for assembling individual refractory bricks on-site, leading to prolonged downtime and economic losses.
Innovation Solution
The development of integral self-supporting refractory components formed by bonding multiple refractory bricks or blocks with a bonding agent, allowing for off-site fabrication and transportation, which reduces labor costs and enhances construction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual refractory bricks are assembled on-site to construct massive refractory structures, then the structural integrity and thermal performance are maintained, but the construction time and labor costs increase significantly
Solution Approach 1:
The refractory structure is divided into modular pre-fabricated components (segments) that are manufactured off-site and then assembled on-site. Each segment is a self-contained unit with standardized connection interfaces, allowing for rapid assembly while maintaining the overall structural integrity of the massive refractory structure.
Solution Approach 2:
The refractory components are pre-fabricated and pre-assembled into modular segments before being transported to the construction site. This preliminary action allows for quality control and structural verification in a controlled manufacturing environment, reducing on-site assembly time and ensuring reliability.
2Reliability
If individual refractory bricks are assembled on-site, then the structural requirements are met, but the labor costs and construction complexity increase
Solution Approach 1:
The complex refractory structure is segmented into standardized modular components with uniform connection interfaces. This segmentation simplifies the construction process by reducing the variety of individual brick types and assembly operations, while maintaining thermal performance through consistent material composition in each segment.
Solution Approach 2:
The modular segments are designed with universal connection interfaces and standardized dimensions that allow them to be used across different positions in the refractory structure. This universality reduces construction complexity by eliminating the need for specialized assembly procedures for each location while ensuring thermal performance requirements are met.
3Productivity
If monolithic refractory components are fabricated off-site, then labor costs and assembly time are reduced, but the manufacturing complexity and transportation requirements increase
Solution Approach 1:
Large monolithic refractory components are segmented into smaller modular units that can be more easily manufactured off-site, transported, and assembled on-site. This segmentation reduces manufacturing complexity by working with smaller, more manageable pieces while maintaining high assembly efficiency through standardized connection systems.
Solution Approach 2:
The refractory components are designed with standardized connection interfaces that enable assembly in multiple dimensions. This allows for flexible configuration of modular segments to create various structural forms, improving productivity while managing manufacturing complexity through systematic design approaches.
4Adaptability or versatility
If massive refractory structures are constructed using traditional brick-by-brick methods, then material availability and structural adaptability are maintained, but the downtime and economic loss increase
Solution Approach 1:
The refractory structure is divided into modular segments that can be pre-fabricated using computer-aided design and manufacturing techniques. This allows for precise customization of each segment to meet specific structural requirements while enabling rapid assembly that minimizes downtime and reduces economic loss.
Solution Approach 2:
The manufacturing parameters of the refractory segments are optimized through controlled fabrication processes, allowing for precise control of material properties and dimensional tolerances. This enables high structural adaptability through standardized segments while reducing assembly time compared to traditional brick-by-brick construction.
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 the creation of monolithic refractory structures that can be efficiently assembled and transported, reducing on-site assembly time and labor costs while maintaining structural integrity and thermal performance.
Implementation Method 1
formed by multiple refractory members bonded to one another by a bonding agent
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Refractory components (e.g. crown or rider arches associated with a refractory structure such as coke ovens, glass furnaces, regenerators and the like) are provided by multiple refractory members bonded to one another by a bonding agent to form an integral self-supporting structure.