A system and method for repairing a coke oven having an oven chamber formed from ceramic bricks. A representative system includes a insulated enclosure insertable into the oven chamber and includes removable insulated panels that define an interior area for workers to work in. The insulated enclosure is movable between an expanded configuration and a compact configuration and moving the enclosure to the expanded configuration will decrease the distance between the insulated enclosure and the walls of the oven chamber. Removing the panels exposes the ceramic bricks and allows workers within the interior area to access and the bricks and repair the oven chamber while the oven chamber is still hot. A loading apparatus lifts and inserts the insulated enclosure into the oven chamber. The insulated enclosure can be coupled to additional insulated enclosures to form an elongated interior area.

Refractory tile systems for covering an internal wall of a high temperature furnace or boiler are described. The systems may comprise a base tile having a front face and a back face, and a shielding tile having a front face and a back face. The back face of the base tile may comprise one or more attachment points for mounting the base tile to the internal wall using an anchoring system, wherein the shielding tile is equipped with a protrusion along a first side, extending from the back face of the shielding tile and adapted to stably arrange the shielding tile in a suspended position from the base tile when mounted to the internal wall, and an overhang along a second side opposite the first side and extending from the front side of the shielding tile, such that in a mounted position, the overhang partially covers an adjacent shielding tile.

A stave comprising a housing, an inner cooling fluid circuit comprising a cooling fluid inlet, a cooling fluid outlet and one or more cooling fluid pipes housed within, or cooling fluid passageways defined by, the housing, wherein each cooling fluid pipe and/or passageway is in direct or indirect fluid communication with the cooling fluid inlet and the cooling fluid outlet; and a manifold, integral with or disposed on or in the housing, that provides support for installation of the stave on a furnace shell; wherein the manifold has one or more inlet pipes, or defines one or more inlet passageways, for providing cooling fluid to the cooling fluid inlet of the cooling fluid circuit of the housing; and wherein the manifold has one or more outlet pipes, or defines one or more outlet passageways, for receiving cooling fluid from the cooling fluid outlet of the cooling fluid circuit of the housing.

The campaign lives are extended and the risks of process gas leaks past seals are reduced by improved stave coolers that each hang together inside steel shelled furnaces by a single neck extended out through a steel jacketed collar. All the coolant circuits inside the stave cooler are collected and grouped together to pass inside through the one collar. The steel in the collar is matched to the steel used in the containment shell, and a matching steel weld seals them together. Thermal stresses are thereby prevented from accumulating over separation distances as a consequent of the steel's coefficient of expansion. A single point of penetration has no separation distance to another.

Cast-iron and cast-copper stave coolers improve the campaign lives of furnaces with steel shelled vessels. Each stave cooler has a single rectangular body with one-only protruding neck on its back that includes a steel collar adaptor. All the coolant piping passes in a group through the protruding neck from two or more independent coolant circuits inside the stave body. Such stave coolers are configured to depend entirely for all their vertical mechanical support on a single hanging of the protruding neck as a through-bulkhead in a single corresponding penetration of the containment shell. Thus, a single annular welded steel-to-steel gas seal around the through-bulkhead is all that's needed inside the steel containment shell for each stave cooler. Coolant piping is laid flat in a single common layer, inside to a hot face. Cast-copper stave cooler hot faces include an abrasion resistant layer that extends campaign lives beyond ten years.

Improved vertically orientated metal smelting or converting furnaces, in which at least a portion of its steel shelled vessel is cylindrical. At least one ringed row of horizontal coolers are fixed to the steel vessel shoulder-to-shoulder to form a lintel shelf that cantilevers inward. Such lintel shelf is above the bath zone of the furnace and fully supports a refractory brick lining and interdigitated horizontal coolers above. Below, in the bath zone, the weight of another lining of refractory brick is supported by the floor and the outside of the lining bears against several vertical bathline coolers. The advantage of the improvements include relieving the weight of the upper refractory brick lining and horizontal coolers from the lower bathline lining of refractory brick. Without having to bear such weight, the lower bathline lining of refractory brick can be safely allowed to corrode and thin beyond conventional minimums.

A structure hanger for suspending bricks and brick structures in a high temperature furnace. The structure hanger has a plurality of column arms, at least one upper flange and at least one lower flange. Each column arm can extend between one upper flange and one lower flange of the structure hanger. Each column arm can have a curved shape. At least one lower flange can be removably attached or removably secured to a refractory brick flange of the brick.

A fired precast block prevents itself from dropping off early due to corrosion and increases service life of a blast furnace runner, etc. when used in a very vulnerable portion of the blast furnace runner, etc., and can be produced at low costs. The fired precast block has an upper surface to contact molten metal or slag, a lower surface opposing the upper surface, and a plurality of side surface. The fired precast block is used by being embedded in a castable in such a manner that the upper surface is exposed from the castable and the lower surface and the plurality of side surfaces contact the castable. Each side surface of at least one opposing pair of side surfaces includes a planar portion and an uneven portion. The uneven portion has at least one groove-shaped concave portion.

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.

A refractory layer structure includes a plurality of refractory layers stacked on each other. Each of the refractory layers includes refractory bricks. Each of the refractory bricks is formed as a cuboid having a pair of oppositely positioned first diverging sides and a pair of oppositely positioned second diverging sides. The first diverging sides diverge away from each other from a top to a bottom of the refractory bricks. The second diverging sides diverge away from each other from the bottom to the top of the refractory bricks. The first diverging sides and the second diverging sides are connected to each other. Each of the first diverging sides have a first diverging side protrusion projecting from a top surface thereof. Each of the second diverging sides have a second diverging side protrusion projecting from a top surface thereof.