A furnace containment structure includes a roof assembly including at least one layer of refractory material that includes a first layer of refractory material, a plurality of sidewalls, a plurality of pockets disposed in the first layer of ceramic refractory material, each pocket including a retainer that is spaced apart from sides of the pocket by gaps when the roof assembly is at room temperature, an upper plate disposed above the first layer of refractory material, and a first plurality of suspension rods that pass through first holes in the at least one layer of refractory material and the upper plate, wherein the plurality of suspension rods mechanically couple the retainers to the upper plate to retain the at least one layer of refractory material. The structure can use materials with different thermal expansion rates without cracking at elevated temperatures.

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.

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.

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.

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.

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.

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).

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).

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.

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.