High heat flux furnace cooler comprise CuNi pipe coils cast inside pours of high purity (99%-Wt) copper. The depth of front copper cover over the pipe coils in the hot face to manufacture into the casting is derived from a projection of the thermal and stress conditions existing at the cooler's end-of-campaign-life. CFD and/or FEA analyses and modeling is used for a trial-and-error zeroing in of the optimum geometries to employ in the original casting of CuNi pipe coils in high purity copper casting. Individual pipe coil positions to cast inside a copper casting mold are secured with devices that will not melt, cause thermal shear stresses, or be the source of contaminations or copper defects. Pipe bonding to the casting results because the differential coefficient of expansions of the pipes' and the casting's copper alloys involved do not exceed the yield strength of the casting copper during operational thermal cycling.

A method of treating refractory-lined equipment includes accessing an interior of the refractory-lined equipment with an equipment repair apparatus, wherein the equipment repair apparatus includes a robotic arm and one or more end effectors coupled to an end of the robotic arm, inspecting refractory material that lines an inner wall of the refractory-lined equipment with a first end effector coupled to the end of the robotic arm, removing damaged refractory material from the inner wall with a second end effector coupled to the end of the robotic arm, removing one or more anchors from the inner wall with a third end effector coupled to the end of the robotic arm, and installing new refractory material on the inner wall with a fourth end effector coupled to the end of the robotic arm.

A furnace stave comprising a plurality of internal channels or conduits for circulating cooling fluid through the stave; an inlet and an outlet channel associated with each internal channel or conduit; wherein one of the internal channels or conduits is disposed in a protrusion from the stave.

A high-temperature 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.

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.

An ultra-low thermal mass refractory article includes fibers impregnated with a colloidal inorganic oxide. The refractory article has at least one of the following properties: (i) a density of 500 kg/m.sup.3 to 1500 kg/m.sup.3; (ii) a thermal conductivity of 1.0 Wm/K or less at 700° C.; and/or (iii) a linear thermal shrinkage at 1400° C. of less than 2.5%.

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.

A composite heat insulating lining includes an upper lining and a lower lining. The upper lining and the lower lining each include an inorganic fiber prefabricated layer, and the inorganic fiber prefabricated layer is configured to reduce the heat conductivity of the lining, thereby reducing heat loss. In addition, existing inorganic fiber materials are generally not resistant to high temperature. The composite heat insulating lining provided according to the present application is provided with a refractory coating on a surface of the inorganic fiber prefabricated layer to avoid direct heating of the inorganic fiber prefabricated layer, thereby avoiding high temperature damage to the inorganic fiber prefabricated layer, and improving the service life of the composite heat insulating lining. An ethylene cracking furnace is further provided according to the present application, which includes any one of the above composite heat insulating linings.

A furnace structure includes a roof assembly of at least one layer of refractory material, and a metal plate that covers the at least one layer of refractory material and is configured to dissipate heat from the furnace structure; a plurality of sidewalls fixed to the roof, each of the sidewalls comprising refractory material at an interior surface and a metal wall plate at an outer surface; and a plurality of infrared emitters disposed in an opening in at least one of the refractory material of the sidewalls or the refractory material of the roof.