Many substantially identical refractory bricks are assembled into completed horizontal ring rows neatly nested into laterally curved copper stave coolers surrounding the ring. Each brick locks into horizontal channels between pairs of parallel horizontal protruding ribs on the hot faces of the stave coolers. Every stave cooler is provisioned with a full covering of the refractory bricks after the stave cooler is mounted inside a corresponding steel containment shell. None of the refractory bricks are permitted to be finished bridging between adjacent stave coolers in the same horizontal row. Each brick is installed in their respective stave coolers with crushable or deformable mortar filling the channels. Each brick hooks a toe just under and into an upper of the pair of horizontal ribs, and then rotates in down with favorably oriented and directed earth's gravity to stay in place at least until a next upper row of bricks in a superior horizontal ring lock them in a second way.

Many substantially identical refractory bricks are assembled into completed horizontal ring rows neatly nested into laterally curved copper stave coolers surrounding the ring. Each brick locks into horizontal channels between pairs of parallel horizontal protruding ribs on the hot faces of the stave coolers. Every stave cooler is provisioned with a full covering of the refractory bricks after the stave cooler is mounted inside a corresponding steel containment shell. None of the refractory bricks are permitted to be finished bridging between adjacent stave coolers in the same horizontal row. Each brick is installed in their respective stave coolers with crushable or deformable mortar filling the channels. Each brick hooks a toe just under and into an upper of the pair of horizontal ribs, and then rotates in down with favorably oriented and directed earth's gravity to stay in place at least until a next upper row of bricks in a superior horizontal ring lock them in a second way.

An abrasion-resistant material for the working face of a metallurgical furnace cooling element such as a stave cooler or a tuyere cooler having a body comprised of a first metal. The abrasion-resistant material comprises a macro-composite material including abrasion-resistant particles which are arranged in a substantially repeating, engineered configuration infiltrated with a matrix of a second metal, the particles having a hardness greater than that of the second metal. A cooling element for a metallurgical furnace has a body comprised of the first metal, the body having a facing layer comprising the abrasion-resistant material. A method comprises: positioning the engineered configuration of abrasion-resistant particles in a mold cavity, the engineered configuration located in an area of the mold cavity to define the facing layer; and introducing molten metal into the cavity, the molten metal comprising the first metal of the cooling element body.

Many substantially identical refractory bricks are assembled into completed horizontal ring rows neatly nested into laterally curved copper stave coolers surrounding the ring. Each brick locks into horizontal channels between pairs of parallel horizontal protruding ribs on the hot faces of the stave coolers. Every stave cooler is provisioned with a full covering of the refractory bricks after the stave cooler is mounted inside a corresponding steel containment shell. None of the refractory bricks are permitted to be finished bridging between adjacent stave coolers in the same horizontal row. Each brick is installed in their respective stave coolers with crushable or deformable mortar filling the channels. Each brick hooks a toe just under and into an upper of the pair of horizontal ribs, and then rotates in down with favorably oriented and directed earth's gravity to stay in place at least until a next upper row of bricks in a superior horizontal ring lock them in a second way.

Many substantially identical refractory bricks are assembled into completed horizontal ring rows neatly nested into laterally curved copper stave coolers surrounding the ring. Each brick locks into horizontal channels between pairs of parallel horizontal protruding ribs on the hot faces of the stave coolers. Every stave cooler is provisioned with a full covering of the refractory bricks after the stave cooler is mounted inside a corresponding steel containment shell. None of the refractory bricks are permitted to be finished bridging between adjacent stave coolers in the same horizontal row. Each brick is installed in their respective stave coolers with crushable or deformable mortar filling the channels. Each brick hooks a toe just under and into an upper of the pair of horizontal ribs, and then rotates in down with favorably oriented and directed earth's gravity to stay in place at least until a next upper row of bricks in a superior horizontal ring lock them in a second way.

An electrode seal for use in a metallurgical furnace, the furnace comprising a furnace space heated by electrodes extending through an aperture into the furnace space. The electrode seal comprises at least three sets of shoes in consecutive lateral contact, each shoe having a biasing member for biasing a surface of the shoe toward one of the electrodes thereby allowing the one electrode to longitudinally move within the electrode seal while providing electrical insulation between the electrode and the aperture.

The present disclosure discloses a refractory protection layer for a metallurgical furnace, which includes a insulating layer, a permanent layer built with a refractory brick and arranged on the insulating layer, a working layer built with a refractory brick and arranged on the permanent layer, and a first anti-permeation layer made of ramming mass and arranged on the working layer. The refractory protection layer for the metallurgical furnace described in the present disclosure embodiments has both high temperature resistance and good permeability resistance.

All of a cast-iron or cast-copper stave cooler's weight is supported inside a furnace containment shell by single gas-tight steel collar on the backside. All the coolant piping in each cooler has every external connection collected and routed together through the one steel collar. A wear protection barrier is disposed on the hot face. Such is limited to include at least one of horizontal rows of ribs and channels that retain metal inserts or refractory bricks, or pockets that assist in the retention of castable cement and/or accretions frozen in place from a melt, or an application of an area of hardfacing that is welded on in bead, crosshatch, or weave pattern.

All of a cast-iron or cast-copper stave cooler's weight is supported inside a furnace containment shell by single gas-tight steel collar on the backside. All the coolant piping in each cooler has every external connection collected and routed together through the one steel collar. A wear protection barrier is disposed on the hot face. Such is limited to include at least one of horizontal rows of ribs and channels that retain metal inserts or refractory bricks, or pockets that assist in the retention of castable cement and/or accretions frozen in place from a melt, or an application of an area of hardfacing that is welded on in bead, crosshatch, or weave pattern.

Glass furnace regenerators having opposed pairs of side and end walls formed of refractory blocks, wherein at last one of the side and end walls of the regenerator comprise an interlocking plurality of refractory blocks, and wherein the refractory blocks are self-supporting and load-bearing one-piece pre-cast structures of a refractory material. Tie back bars may be provided to operatively connect a wall formed of the refractory blocks to externally provided buckstays to allow relative movement between the refractor blocks forming the wall and the buckstays (e.g., as may be required due to the blocks undergoing thermal expansion during use).