A sidewall for a metallurgical furnace and a metallurgical furnace having the same are described herein. In one example, a sidewall of a metallurgical furnace is provided that includes an outer wall, a hot plate and a buckstay. The hot plate is coupled in a spaced apart relation to the outer wall. The buckstay is mechanically coupled to the outer wall and the hot plate. The buckstay includes a buckstay web extending from a buckstay flange. The buckstay web includes a first end coupled to the buckstay flange, and a second end mechanically and movably coupled to the hot plate.

A refractory article can include a socket including a cavity that is configured to receive a post, a particulate material, and a binder. The binder is configured to bond the post to the socket. The refractory article can include a sleeve coupled to the socket and configured to bond the post to the socket. In an embodiment, the sleeve can bond to the binder. In another embodiment, a collar can be placed between the sleeve and the binder. The collar can be configured to bond the post to the socket. A method of forming a refractory article can include disposing a particulate material within a cavity of a socket and placing a binder material overlying the particulate material.

A clip for supporting a refractory structure and/or a hanger structure. The clip can have a body with two legs connected to a top. A fastener that extends through the top can be adjusted and/or secured to fix a relative position of the clip with respect to the refractory structure and/or the hanger structure. An adjuster that extends through the top, such as a tab connected to or integrated with the top, can be used to adjust a distance, such as a vertical height, of the clip with respect to adjacent fixed structural members. The adjuster can be used to compensate for a distance change resulting from the refractory structure, the hanger structure, one or more adjacent fixed structural members, and/or any other similar structure, bending, flexing and/or otherwise deforming due to exposure of the components to a relatively high temperature.

A refractory insert is provided, including a main body part having a first surface defining a first sidewall, an opposed second surface defining a second sidewall, and an outer peripheral surface separating the first and second surfaces, and a mechanical mating member provided on at least a portion of the outer peripheral surface thereof. The mechanical mating member includes a retention mechanism for controlling and retaining a position of a corresponding mating member in connection therewith.

A high temperature vacuum furnace including a prefabricated tongue-and-groove, low-mass insulation ring assembly hot zone, resulting in decreased energy costs and increased energy efficiency, faster heating and cooling cycles, and expedited maintenance capability resulting in lower maintenance costs. Decreased time of a workpiece in the furnace improves production turnaround and lowers energy costs for each heat treating cycle. Furnace manufacturing is also easier and less expensive compared to prior art vacuum furnaces. A bottom support structure replaces the prior art metal support ring resulting in an approximately 80-85% weight saving in the furnace hot zone. This reduces the time and energy required to heat and cool the furnace components and workpiece.

Mounting hardware for mounting an insulation module on a furnace wall. The hardware comprises a mounting bracket embedded within the module. The bracket has a plurality of flexible tabs, each tab having a fixed end and a free end. The free ends of the tabs are arranged about a central point and are movable (flexible) relative to the fixed ends. A mounting stud is provided having a fixed end attachable to an inner surface of a furnace wall and a free end. The stud extends from the inner surface, and the stud has an annular groove adjacent the fixed end. The stud is dimensioned to extend through the mounting bracket between the free ends of the tabs and to cause the tabs to flex as the bracket moves along the stud from the free end towards the fixed end, wherein the tabs snap and lock into the annular groove when the bracket reaches the annular groove.

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, two branch segments extending from each end of the central segment, and an extension segment extending from each of the four branch segments, to collectively form four unenclosed cell openings that are each semi-hexagonal in shape. Some embodiments include four reinforcement segments with each one extending into a respective cell opening, four voids with each one extending through respective adjacent branch and extension segments, an underbody gap formed under the central segment for refractory interlinking between cell openings, and/or a single stud-welding stud for 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.

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.

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, two branch segments extending from each end of the central segment, and an extension segment extending from each of the four branch segments, to collectively form four unenclosed cell openings that are each semi-hexagonal in shape. Some embodiments include four reinforcement segments with each one extending into a respective cell opening, four voids with each one extending through respective adjacent branch and extension segments, an underbody gap formed under the central segment for refractory interlinking between cell openings, and/or a single stud-welding stud for 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.

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, two branch segments extending from each end of the central segment, and an extension segment extending from each of the four branch segments, to collectively form four unenclosed cell openings that are each semi-hexagonal in shape. Some embodiments include four reinforcement segments with each one extending into a respective cell opening, four voids with each one extending through respective adjacent branch and extension segments, an underbody gap formed under the central segment for refractory interlinking between cell openings, and/or a single stud-welding stud for 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.