REFRACTORY INSERT MEMBERS, REFRACTORY BLOCK ASSEMBLY INCLUDING SAME AND REFORMER FLUE GAS TUNNEL ASSEMBLY INCLUDING SAME

Abstract

A refractory block assembly for a steam reformer furnace tunnel includes a hollow main body, at least one first mechanical mating member defining a protruded portion extending from an upper surface of the main body, at least one second corresponding mechanical mating member defining an opening corresponding to the protruded portion formed in a portion of a lower surface of the main body, and at least one through-hole having openings formed in a first side and an opposed second side of the main body portion. A refractory insert member having mechanical mating features on at least a portion of the outer surface thereof resides within the at least one though-hole of the refractory block.

Claims

1. A refractory block assembly comprising: an refractory block having at least one opening formed therein; and at least one refractory insert member that resides within the at least one opening in the refractory block.

2. The refractory block assembly according to claim 1, wherein said at least one refractory insert member comprises mechanical mating member that engages a corresponding mechanical mating member provided on an inner surface of the at least one opening in the refractory block.

3. The refractory block assembly according to claim 2, wherein the mechanical mating member of the refractory insert member comprises a slot and groove that mechanically engage and retain a corresponding tab provided on the inner surface of the at least one opening of the refractory block.

4. The refractory assembly according to claim 1, wherein the at least one refractory insert member is at least at least one of a gas flow changing plug, a gas flow restricting puck, a gas flow changing cap, and a tie bar cradle.

5. A refractory block assembly for a steam reformer furnace tunnel, the refractory block assembly comprising: a hollow main body portion having an outer peripheral surface defining a first end, an opposed second end, an upper surface, an opposed lower surface, a first side and an opposed second side; at least one through-hole having openings formed in the first side and the opposed second side of the main body portion; a refractory insert member that resides within at least one of the at least one though-hole, the refractory insert member comprising a mechanical mating member that engages a corresponding mechanical mating member provided on an inner surface of the at least one through-hole; at least one first mechanical mating portion defining a protruded portion extending from a portion of the upper surface of the main body portion; and at least one second corresponding mechanical mating portion defining an opening corresponding to the protruded portion formed in a portion of the lower surface the main body portion.

6. The refractory block assembly according to claim 5, wherein the mechanical mating member of the refractory insert member comprises a slot and groove that mechanically engage and retain a corresponding tab provided on the inner surface of the at least one through-hole.

7. The refractory block assembly according to claim 5, wherein the at least one refractory insert member is at least one of a gas flow changing plug, a gas flow restricting puck, a gas flow changing cap, and a tie bar cradle.

8. A refractory insert member comprising: a main body part having a first end, an opposed second end, and an outer peripheral surface; and a mechanical mating member provided on at least a portion of the outer peripheral surface thereof.

9. The refractory insert member according to claim 8, wherein the mechanical mating member comprises at least one slot.

10. The refractory insert member according to claim 9, wherein the mechanical mating member comprises at least two diametrically opposed slots.

11. The refractory insert member according to claim 8, wherein the mechanical mating member comprises at least one flange having at least one slot and a channel, open to the slot, extending around at least a portion of the outer peripheral surface of the main body.

12. The refractory insert member according to claim 11, wherein the mechanical mating member comprises at least one flange having two diametrically opposed slots and a channel, open to the slots, extending around the outer peripheral surface of the main body between the slots.

13. The refractory insert member according to claim 11, wherein the mechanical mating member comprises two parallel flanges separated from one another by the channel located between the flanges, wherein at least one of the flanges has two diametrically opposed slots open to the channel, and wherein the channel extends around at least a portion of the outer peripheral surface of the main body between the slots.

14. The refractory insert member according to claim 8, wherein the refractory insert member is at least one of a gas flow changing plug, a gas flow restricting puck, a gas flow changing cap, and a tie bar cradle.

15. A refractory tunnel assembly for a steam reformer furnace, the tunnel assembly comprising: a plurality of hollow base components, each the base component comprising a plurality of corresponding mechanical mating members; a plurality of hollow wall blocks, each the wall block comprising a plurality of corresponding mechanical mating members that further correspond to the mechanical mating members of the base components, wherein at least a portion of the plurality of wall blocks further comprise at least one through-hole having openings formed in opposed side surfaces thereof; a plurality of hollow lid components, each said lid component comprising a plurality of mechanical mating members that further correspond to said mechanical mating members of said base components and said wall blocks; and one or more refractory insert members that reside within one or more of the though-holes in said wall blocks; wherein said base components are arranged to extend in a horizontal arrangement direction defining a width of the tunnel assembly and a longitudinal arrangement direction defining a length of the tunnel assembly; wherein the wall blocks are stacked upon and mechanically interconnected to the base components via the corresponding mechanical mating members in a vertical arrangement direction and along the longitudinal arrangement direction, and are stacked upon one and mechanically interconnected to another via the corresponding mechanical mating members, without the use of mortar, in both the vertical and longitudinal arrangement directions, to define two parallel tunnel walls, spaced a distance apart from one another in the horizontal arrangement direction, wherein the tunnel walls extend upwardly from the base components in the vertical arrangement direction and along the length of the tunnel assembly on the base components; and wherein the plurality of lid components are stacked upon and mechanically interconnected to the wall blocks via the mechanical mating members, without the use of mortar, in the vertical arrangement direction and along the longitudinal arrangement direction, so that the lids extend along the longitudinal arrangement direction and the horizontal arrangement direction in order to cover the distance between the tunnel walls along at least a portion of the length of the tunnel assembly.

16. The refractory tunnel assembly according to claim 15, wherein the base components, the wall blocks, the lid components, and the refractory insert members all comprise the same material.

17. The refractory tunnel assembly according to claim 15, further comprising at least one tie bar extending between the tunnel walls in the horizontal extension direction and having a first end located in a portion of a first refractory insert member and a second end located in a portion of an opposed second refractory insert member.

18. The refractory tunnel assembly according to claim 15, wherein the at least one refractory insert member comprises a mechanical mating member that engages a corresponding mechanical mating member provided on an inner surface of the at least one through-hole of the wall blocks.

19. The refractory block according to claim 18, wherein the mechanical mating member of the refractory insert member comprises a slot and channel that mechanically engage a corresponding tab provided on the inner surface of the at least one through-hole of the wall blocks.

20. The refractory assembly according to claim 15, wherein the at least one refractory insert member is at least one of a gas flow changing plug, a gas flow restricting puck, a gas flow changing cap, and a tie bar cradle.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] For a better understanding of the nature and object of the present invention, reference should be made to the following detailed description of a preferred mode of practicing the invention, read in connection with the accompanying drawings, in which:

[0052] FIG. 1A is a perspective cut-view of a conventional hydrogen reformer furnace, and FIG. 1B is a sectional end view of the furnace shown in FIG. 1A;

[0053] FIG. 2 is a perspective view of a conventional tunnel assembly used in the furnace shown in FIGS. 1A and 1B;

[0054] FIG. 3 is a perspective view of a conventional solid lid;

[0055] FIG. 4 is a perspective view of a conventional single tongue and grove type block (brick);

[0056] FIG. 5 is a perspective view of a conventional double tongue and grove type block (brick);

[0057] FIG. 6 is an end view of a conventional hollow lid;

[0058] FIG. 7 is a perspective view of the conventional hollow lid shown in FIG. 6;

[0059] FIG. 8 is a perspective view of a conventional off-set lid;

[0060] FIG. 9 is a perspective view of a conventional tongue and groove lid;

[0061] FIG. 10 is a perspective top view of a half block (brick) according to one aspect of the present invention;

[0062] FIG. 11 is a perspective top view of a full block (brick) according to one aspect of the present invention;

[0063] FIG. 12 is a perspective bottom view of the full block shown in FIG. 11;

[0064] FIG. 13 is a sectional end view of two blocks shown in FIG. 11 in a stacked arrangement;

[0065] FIG. 14 is a sectional end view of the stacked arrangement shown in FIG. 13 under rotational force to illustrate that the stacked blocks to not disengage;

[0066] FIG. 15 is an end view of prior art blocks shown in FIG. 4 under rotational force to illustrate that those blocks do disengage under the same type of rotational force;

[0067] FIGS. 16A and 16B are perspective views of a full block including at least one though-hole (two as shown) according to the present invention, and FIG. 16C is a cut-view of the full block shown in FIGS. 16A and 16B;

[0068] FIG. 17 is a perspective top view of a full width base component according to the present invention;

[0069] FIG. 18 is a perspective view of a tie bar (tie rod);

[0070] FIG. 19A is a perspective view of a tie bar cradle insert member 15 according to one aspect of the present invention, FIG. 19B is a perspective view of the full block shown in FIGS. 16A-C and a tie rod cradle insert member 15 being inserted therein, and FIG. 19C is a perspective view of the assembly including the installed tie bar cradle insert member 15, FIG. 19D is a perspective view of the full block shown in FIGS. 16A-C and a tie rod cradle insert member 151 according to another aspect being inserted therein, and FIG. 19E is a perspective view of the assembly including the installed tie bar cradle insert member 151.

[0071] FIG. 20 is a perspective view of two full blocks according to FIGS. 16A-C and a tie rod according to FIG. 18 situated in the respective tie bar cradles 15 defining an assembly and spanning the horizontal distance between the opposed blocks;

[0072] FIG. 21A is a perspective view of a flow constricting plug insert member 130 according to one aspect of the present invention, FIG. 21B is a perspective view of a flow constricting plug insert member 136 according to another aspect of the present invention being installed in the block 100 shown in FIG. 16, and FIG. 21C is a front view of the installation process shown in FIG. 21C, FIG. 21D is a is a perspective view of a flow constricting plug insert member 230 according to another aspect, FIG. 21E is a is a perspective view of a flow constricting plug insert member 330 according to another aspect, and FIG. 21F is a is a perspective view of a flow restricting plug insert member (puck) 430 according to another aspect;

[0073] FIG. 22A is a perspective view of a flow directing cup insert member according to the present invention and a block shown in FIG. 16, and FIG. 22B is a perspective view of the flow directing cup insert member installed in the block;

[0074] FIG. 23 is a perspective top view of a lid;

[0075] FIG. 24 is a perspective bottom view of the lid shown in FIG. 23;

[0076] FIG. 25 is a perspective view of a tunnel assembly according to the present invention;

[0077] FIG. 26 is a side view of the tunnel assembly shown in FIG. 25;

[0078] FIG. 27 is an end view of the tunnel assembly shown in FIGS. 25 and 26;

[0079] FIG. 28 is a perspective view of the tunnel assembly shown in FIG. 25 with some wall blocks removed to show the location of the tie bars; and

[0080] FIG. 29 is a perspective view of the tunnel assembly shown in FIG. 25 built up higher and having double lids.

DETAILED DESCRIPTION OF THE INVENTION

Blocks (Also Referred to Herein Interchangeably as Bricks)

[0081] The flue gas tunnel according to the present invention comprises a plurality of refractory blocks or bricks, which are used in conjunction with one or more refractory insert members to define a refractory block assembly. While standard bricks or pre-cast brick shaped members can be used, as noted above, the refractory blocks are preferably engineered with precision interlocking mechanical mating features to facilitate stacking interconnection to form the free-standing tunnel walls without the use of mortar. These mechanical mating features are also specifically designed to allow for thermal expansion in service while simultaneously preventing the wall from becoming disassembled prematurely.

[0082] One example of a mating feature has a geometry that requires horizontal installation and prevents the block from becoming disassembled vertically. FIG. 10 shows a half brick 1 and FIG. 11 shows a full brick 10. FIG. 12 is a bottom view of the full brick 10 shown in FIG. 11. It should be understood that the corresponding bottom view of the half brick 1 shown in FIG. 10 (not shown) would be same as that shown in FIG. 12, only half the size. A standard brick has dimensions of, for example, 6.5 in W18 in L10 in T (tall), but the design is applicable for bricks as small as 2 in W4 in L2 in T and for bricks as large as 9 in W24 in L18 in T, as well. Preferably, each block (brick) has a weight in a range of 20-70 lb, more preferably 40-50 lb, so that one person can readily maneuver the blocks alone, while reducing the total number of blocks needed to construct the tunnel wall to the smallest number possible.

[0083] It should be noted that although the blocks 1, 10 as shown do not include any through-holes, either type of block 1, 10 can be modified or manufactured to include one or more though-holes, as discussed below in connection with FIGS. 16A-1C. An example of a half-block 1A including at least one though-hole (and having a refractory insert member installed therein) is shown and described below in conjunction with the refractory block assemblies and tunnel assembly structure of FIGS. 25-29.

[0084] Each of the bricks 1, 10 has an outer peripheral surface defining a first end (1a, 10a), an opposed second end (1b, 10b), an upper surface (1c, 10c) and an opposed lower (bottom) surface (1d, 10d). These bricks 1, 10 are hollowed out to remove all possible material from non-critical areas. Preferably, the wall thickness t (see, e.g., FIG. 12) walls of these bricks 1, 10 is in a range of 0.5-1.5 in, preferably 0.625-0.875 in. The resultant tunnel assembly has only about 60% of the weight of a conventional tunnel. The hollowed-out portions define one or more, preferably a plurality of cavities 2 in the respective blocks 1, 10.

[0085] The upper surfaces 1c, 10c of the blocks 1, 10 each include a male part of the precision interlocking mechanical mating features of the refractory blocks according to the present invention. The protruding portion 3 is elevated a distance from the surface 1c, 10c to define a geometrical member that extends from the block 1, 10 and serves as a locking part that fits precisely into the opening 4 formed in the lower surface 1d, 10d of the blocks 1, 10. As shown, the protruding portion 3 is a substantially rectangular elevation with chamfered corners and a circular opening 3a passing through its center and in communication with a cavity 2. The circular opening 3a is merely a function of manufacturing and material removal considerations, and is not critical. As shown in FIGS. 10 and 11, the openings 3a are in communication with the cavities 2. This is not always the case, however, as described in more detail below.

[0086] While the exact shape of the protruding portion 3 is not necessarily limited to the shape shown here, it is preferably a geometric match to the shape of the corresponding opening 4, with a slight off-set to accommodate manufacturing tolerances. The protruding portions 3 of the blocks 1, 10 must fit precisely within the openings 4 of the vertically adjacent blocks 1, 10 to securely engage the vertically adjacent blocks 1, 10 to one another to facilitate the construction of free-standing tunnel walls without the use of mortar. There must also be sufficient tolerance to account for the thermal expansion considerations discussed above, and to maintain contact to prevent buckling.

[0087] The opening 4 communicates with the cavities 2 of the blocks 1, 10, and receives the protruding portion 3 in a tight, interlocking manner to securely connect the blocks 1, 10 to one another, without mortar, in a vertically stacked manner, as shown in FIG. 13. The shape of the opening 4 is not critical, so long as it precisely corresponds in shape and size to the shape and size of the protruding portions 3, in consideration of the mechanical factors and thermal concerns discussed above.

[0088] The importance is the geometric match with a slight off-set between the corresponding protruding portion 3 and opening 4 into which the protruding portion 3 fits. Preferably, the off-set is in a range of 0.020 in to 0.060 in. The minimum off-set is dictated by manufacturing tolerance capabilities resulting in block to block variability. There must be sufficient height and tightness to securely engage if buckling occurs. Preferably, the overall height h of the protruding portion 3, or distance that the protruding portion 3 extends from the upper surface 1c, 10c of the blocks 1, 10, is at least 0.75 in, in order to ensure sufficient engagement with the opening 4 and prevent buckling. The dimensions of the opening 4 should be as tight to the protruding portion as possible with allowance for manufacturing variation. Ideally, uniform wall thickness balanced with manufacturing needs governs the dimensions.

[0089] The individual blocks 1, 10 further include additional mechanical mating features, such as a tab on one end and a groove on the other end, with a gap provided that allows each block to expand with increasing operating temperature until its seals against the blocks on either side thereof in the horizontal arrangement direction. As shown in FIGS. 10-12, the first sides 1a, 10a of the blocks 1, 10 include a groove or slot 5, and the opposed second sides 1b, 10b are formed to include a corresponding tab or protrusion 6 that vertically fits into the corresponding groove 5 of a horizontally adjacent block 1, 10. Preferably, the groove is larger than the tab by a minimum of manufacturing variation; preferably, the tab is 30-75% of the overall width of the block.

[0090] A compressible high temperature insulation fiber (not shown) can also be provided, placed in the groove 5 in order to reduce gas bypass while accommodating for a range of temperature fluctuations in service. The fiber is specified to have sufficient compression variability so as to reduce gas bypass over a wide range of operating temperatures from 600 C.-1200 C. This fiber can also be used in between layers of blocks to prevent point loading. As discussed below, the base components and top lids (covers) both have a similar tab and groove design, and use either a fiber gasket or a fiber braid to reduce gas bypass over the range of operating temperatures.

[0091] Preferably, as the blocks 1, 10 are arranged in the formation of the tunnel wall, the blocks 1, 10 are horizontally off-set by one-half of a block length, or by one set of mechanical mating features, to increase the mechanical robustness of the arrangement (see, e.g., FIG. 25 in connection with blocks 1A, 10 and 100). This arrangement also helps prevent buckling, which is arrested by virtue of the robust and tight tolerance interlocking mechanical mating feature, so that the rotation of one block relative to a block below it does not cause direct contact between the respective protruding portion 3 and the opening 4 to break, as shown in FIG. 14. On the other hand, FIG. 15 shows how rotational forces on prior art tongue and groove blocks (see FIG. 4) can cause separation between the blocks, and direct contact between the respective tongue and groove features significantly breaks, which leads to wall collapse.

[0092] The mechanical mating features described above add redundancy to the system by mechanically engaging the blocks, which prevents the tunnel wall from leaning and falling over without requiring that mating features be sheared off or otherwise break through the wall of the block to which they are connected.

[0093] In order for the tunnel to properly act as a flue for the exit of the furnace, it must have variable inlet conditions (openings in the walls), for example, which typically allow more gas to enter the tunnel farthest from the exit, and less gas to enter the tunnel closer to the exit (or in any manner dictated by the processing concerns). The typical arrangement creates a more uniform distribution of gas and temperature in the furnace. As noted above, conventional tunnel wall designs simply utilize half bricks to create gaps in the walls as various locations. However, such conventional half bricks create unsupported locations on top of the square openings, creating locations for failures.

[0094] As shown in FIGS. 16A-C, the tunnel system (see FIGS. 25-59) utilizes refractory blocks 1A and 100 that include one or more through-holes 7 formed therein in order to allow gas to enter the tunnel. This design evenly distributes the load created by the through-holes 7 to the surrounding material. The through-holes 7 can be formed when the bricks 1A, 100 are initially formed (e.g., cast), or can be formed later by machining or any suitable process.

[0095] The block 100 has an outer peripheral surface defining a first end 100a, an opposed second end 100b, an upper surface 100c, and an opposed lower (bottom) surface 100d. Although a full block 100 is shown, it should be understood that a half-block could also be used, which would be the same as block 100, but only half the size (see, e.g., the description in connection with FIGS. 10 and 11). Like the structure shown and described in connection with shown in FIGS. 10-12, the first sides 100a of the blocks 100 include a groove or slot 5, and the opposed second sides 100b are formed to include a corresponding tab or protrusion 6 (not shown) that vertically fits into the corresponding groove 5 of a horizontally adjacent block 100. Preferably, the groove is larger than the tab by a minimum of manufacturing variation; preferably, the tab is 30-75% of the overall width of the block. A compressible high temperature insulation fiber (not shown) can also be provided, placed in the groove 5 in order to reduce gas bypass while accommodating for a range of temperature fluctuations in service. The fiber is specified to have sufficient compression variability so as to reduce gas bypass over a wide range of operating temperatures from 600 C.-1200 C. This fiber can also be used in between layers of blocks to prevent point loading.

[0096] Preferably, as the blocks 100 are arranged in the formation of the tunnel wall, the blocks 100 are horizontally off-set by one-half of a block length, or by one set of mechanical mating features, to increase the mechanical robustness of the arrangement (see, e.g., FIG. 25 in connection with blocks 1A and 10). This arrangement also helps prevent buckling, which is arrested by virtue of the robust and tight tolerance interlocking mechanical mating feature, so that the rotation of one block relative to a block below it does not cause direct contact between the respective protruding portion 3 and the opening 4 to break.

[0097] The through-holes 7 of the blocks 100 can have any geometry, but preferably have a circular or semi-circular shape. The size of the through-holes 7 can vary from 1 in.sup.2 up to substantially to the full size of the block 100, which is typically around 144 in.sup.2, but are preferably 12 in.sup.2-36 in.sup.2. For example, in FIGS. 16A-16C, the though-holes 7 have a diameter of approximately 4.5 inches. Blocks 100 preferably have one or two through-holes 7 per block, but could have multiple holes in various locations to facilitate the same end result, as desired. These through-holes 7 are preferably be closed, i.e., do not communicate with the interconnected internal cavities 2 of the blocks 100 that form an internal area of the tunnel wall, as shown (see FIG. 16C), or instead, a number of blocks could have through-holes that are open to the internal area of the tunnel wall.

[0098] As shown in FIGS. 16A-16C, the opening 3b in the protruding portion 3 is simply a removed-material portion, and does not communicate with (not in fluid communication with) the cavity 2. As best shown in FIGS. 16B and C, the through-hole 7 is like a tube that passes though the cavity 2, but the internal surface 7a of the through-hole 7 is not in fluid communication therewith, and the through-hole 7 (though which the gasses pass) is therefore closed to the cavities 2 (and therefore the internal surface area of the tunnel wall) by virtue of the external surface 7b of the through-hole 7.

[0099] A mechanical mating member, such as one or more tabs 8, are provided on the inner surface 7a (i.e., inner diameter; see FIGS. 16B, 16C) of the through-hole 7, to serve as a mechanical fastening feature that interlocks with corresponding mating features provided on various refractory insert members. As shown in FIGS. 16A-C, the tabs 8 are preferably located on diametrically opposed portions of the inner surface 7a of the through-hole 7. Although the exact dimensions of the tabs 8 are not expressly limited by anything except the corresponding mating geometry of the insert members (described below), these tabs 8 have a preferred dimension of high (protruding from the inner through-hole surface 7a), long (axial distance), and 1.75 wide (radially). While the size of the tabs 8 and the shape of the tab 8 can readily be modified, it is preferred that the aspect ratio of 2:1, length: height is maintained. Preferably, the size of the tab 60 or less with respect to the circumference of the inner diameter (inner surface) 7a of the through-hole 7, but must necessarily be only slightly less than the corresponding receiving part (opening/slot) on the insert member, in order to by-pass the opening and fit therein or within the receiving groove (once rotated).

Base Component

[0100] The base component 30 is shown in FIG. 17. A plurality of base components 30 run the length of the tunnel and span the horizontal width w of the tunnel to connect the two walls together using the same mating features as the wall blocks 10, 100 described above (see, e.g., FIGS. 25-29).

[0101] Each base component 30 has an outer peripheral surface with an upper surface 30c and an opposed lower (bottom) surface 30d on which the interlocking mechanical mating features protruding portions 33, and corresponding openings 34 (not shown) are respectively formed. The protruding portions 33 correspond to the protruding portions 3 described above in connection with the bocks 1, 10, 100, and the openings 34 correspond to the openings 4 described above in connection with the blocks 1, 10, 100. The same critical dimensional requirements for the mechanical mating members and wall thicknesses discussed above apply to the base components, as well. Preferably, each base component 30 has a total weight in a range of about 60-100 lb, more preferably less than about 70 lbs.

[0102] The protruding portions 33 are provided on the upper surface 30a of the base components 30 proximate the two opposed ends 30a, 30b, so as to correspond to the laterally (horizontally) opposed locations of the tunnel walls to be built thereon. The openings 34 are provided in the bottom surface 30d of the base component 30 in corresponding locations. In some embodiments, the base component 30 has a plurality of cavities from which unnecessary material has been removed to reduce the weight of the base block. The openings 32 are material removed portions and may or may not communicate with such cavities, and a plurality of additional cavities are provided along the length of the base component 30, separated by interior block walls having sufficient thickness to provide enough material to ensure the structural integrity of the component is maintained. The wall thickness is preferably in a range of 0.5 to 1.5 in, preferably 0.625 to 0.875 in.

[0103] As noted above, it is important that the size and material of the base component 30 is substantially the same as that of the lid (discussed in more detail below) in order to properly and effectively compensate for thermal and stress factors, although the base is a heavier component, as one skilled in the art can appreciate.

Lids (Also Referred to Herein Interchangeably as Covers)

[0104] The span of the top lid 60 can be as small as 12 in, or as wide as 60 in, although the preferred size is a range of 24 in to 36 in. Preferably, each lid component has a total weight in a range of 50-100 lb, more preferably in a range of 60-80 lbs.

[0105] As shown in FIG. 23, the upper surface 60c of lid 60 has a flat top with angled sides. The upper surface 60c of the lid also includes the same interlocking mechanical mating features 63, 64 as described above in connection with the blocks 1, 10, 100 and the base components 30. In the case of the lid 60, the protruded portions 63 serve two functions. First, the protruding portions 63 provide mechanical mating features in connection with the corresponding openings 4 on other wall blocks 10, 100 in the same manner discussed above, which enable the lid 60 to be used in an assembly where the lid 60 is not the only topmost component, but where additional tunnel wall blocks 10, 100 are instead placed on top of the lid 60, and the walls are continued vertically upward, providing a stacked-lid arrangement (see, e.g., FIG. 29). Second, since the protruding portions 63 extend a distance of at least 0.5 in above (in the vertical direction) the overall surface geometry of the lid 60, this allows for the placement of a plywood board on top of the lid 60 to define a walkway during furnace turnarounds. Because this exists directly above the tunnel walls, the walkway allows workers access into the furnace on top of the tunnels without putting weight onto the center of the unsupported span of the lids, and instead directs all of their weight onto the tunnel walls, where it can be readily supported.

[0106] The lid 60 is also hollowed out from the bottom surface 60d to remove all possible material from non-critical areas, in order to minimize the stress by improving the ratio of force per unit area of the cross section. As shown in FIG. 24, a large central cavity 62 is formed thereby, as well as two smaller cavities 62 in communication with the openings 64 defining the mechanical mating features. The mechanical mating feature (opening) 64 provides engagement with the protruded portions 3 of the blocks 10, 100 forming the walls 8 to securely attach the lid 60 to the walls 8 on either side, spanning the internal tunnel width between wall structure. The critical dimensions of the mechanical mating features are the same as discussed above. Preferably, the wall thickness t of the lids is in a range of 0.5 to 1.5 in, more preferably 0.625 to 0.875 in.

[0107] The lids 60 also have additional mechanical mating features such as the grooves 65 formed on side surface 30f (see FIG. 24) and protrusion or tab 66 formed on side surface 60e (see FIG. 23). These features serve the same purpose and function as the mechanical mating features/expansion gap features 5 and 6 described above in connection with the blocks 1, 10, 100 described above in connection with the base component 30. The position of these mating/expansion features 65, 66 corresponds to the mating alignment with the other lids 60 and the wall blocks 10, 100 stacked thereunder, as described below in more detail in connection with FIGS. 25-28.

Refractory Insert Members

[0108] As described above, the blocks 100 (or 1A) include one or more tabs 8 that are added, cast or pre-formed by machining, for example, on the inner surfaces (inner diameter) 7a of the through-holes 7 of the blocks 100 (see, e.g., FIGS. 16b and 16C). The tabs 8 serve as secure mating features for the specialty refractory insert members that are utilized in the tunnel system. The refractory insert members have corresponding mating features (i.e., openings/slots and grooves) that mechanically engage and/or retain the tabs if rotated (described in more detail below).

[0109] Since the through-hole or opening in the brick (block) 1A, 100 is not limited to the geometry of a circle, the corresponding overall geometry of the refractory insert member is therefore dictated by the overall geometry of the respective through-hole. A circular shape (cylindrical) is preferred. Any of the various refractory insert members according to the present invention can be used in conjunction with any through-hole location in any of the blocks 100 to define a refractory block assembly, and likewise, and such a refractory block assembly can be used in any location of the tunnel system according to the present invention. This provides a modular system and allows for a universal refractory insert-mating tab to be provided on the surface of the openings of the blocks (bricks) that can be used in conjunction with any insert in any location in the tunnel. Such flexibility allows the end user to modify the installation of refractory insert members in any manner they deem necessary depending on the particular processing concerns that they may face.

[0110] Tie Bars (Also Referred to Herein Interchangeably as Tie Rods and Cross Beam Supports) and Tie Bar Cradle Insert Members

[0111] A tie bar is used in the tunnel assembly at various points to secure the walls in place to prevent movement, both inward and outward, as shown in FIGS. 18, 20 and 27-29. One example of a tie bar 50 (also referred to as a tie rod or cross beam support) is shown in FIG. 18. The tie bar 50 engages and supports the tunnel walls in various ways, as described below. The tie bars 50 are placed at various points in the system to improve the overall stability of the tunnels in service, as one skilled in the art can readily determine. The span of the tie bar 50 is substantially the same as the span of the top lid and the base component, which can be as small as 12 in or as wide as 60 in, although the preferred size is a range of 24 in to 36 in (corresponding to the internal width of the tunnel). It is understood that the length of the tie bar is governed strictly by the designed width of the tunnel, with clearance to allow for thermal growth. The cross-sectional diameter of the tie bar 50 is preferably 1-8 in, more preferably 3-4 in.

[0112] As shown in FIGS. 19A-19E, tie bar cradle insert members 15, 151 according to two different aspects of the present invention are cylindrical insert members extending from a first end (15a, 151a) toward an opposed second end (15b, 151b), and having a cylindrical central portion (15c, 151c). As shown in FIGS. 19A-19B, the first end 15a of the tie bar cradle insert 15 includes an annular rim 16 having a central groove 16b and a pair of diametrically opposed openings/slots 16a formed therein, dimensioned to accept and receive the tabs 8, and thereby serve as mechanical mating features in conjunction with the tabs 8 in the through-hole 7 of the block 100 (or 1A). A s shown in FIGS. 19D-19E, the first end 151a of the tie bar cradle insert 151 includes an a pair of parallel annular rims (flanges) 153, 155 having a central groove (channel) 154b therebetween, and a pair of diametrically opposed openings 154a formed at least in the annular rim 153 (both 153 and 154, as shown) to accept and receive the tabs 8, and thereby serve as mechanical mating features in conjunction with the tabs 8 in the through-hole 7 of the block 100.

[0113] The size of the openings/slots 16a, 154a is preferably about 60 or more (at least slightly bigger than the tabs 8) with respect to the circumference of the refractory insert member 15, 151 and the circumference of the through-hole 7, but the critical dimension is dependent mainly upon the size of geometry of the tab 8, and vice versa. One skilled in the art can appreciate the factors needed to design a properly interlocking slot and tab mechanism in the context of the present invention in connection with the disclosure provided herewith. The tie bar cradle inserts 15, 151 are inserted into the through-hole 7 so that the slots 16a, 154a by-pass the tab 8 cast on the inner diameter 7a of the block 100. The tie bar cradle insert 15, 151 are then rotated a sufficient amount, preferably about 90 degrees, far enough to secure it in place in the groove 16b, 154b, from which it cannot readily disengage.

[0114] The respective second ends 15b, 151b of the respective tie bar cradle inserts 15, 151 include a semi-cylindrical portion having interior annular rim features 152 to guide, receive and retain the corresponding annular flanges 51 at the ends 50a, 50b of the tie bar 50 when vertically positioned into place therein (see, e.g., FIG. 20). Again, the design of this portion of the tie bar cradle insert 15, 151 depends on the corresponding geometry of the outer peripheral shape of the flange portions 51 of the respective tie bar 50, which could conceivably have differing geometrical configurations (i.e., it is not limited to the circular-shaped flange shown in FIG. 18, but could have any kind of polygon-shaped or elliptical lip at the end thereof). In both embodiments, there is a shoulder portion, such as a stopper flange 15d, 151d provided between the central cylindrical portion 15c, 151c that is housed within the though-hole 7 and the semi-cylindrical portion that cradles the tie bar 50. The outer diameter of the tie bar cradle insert is slightly smaller than the inner diameter of the through-hole of the block to allow for proper insertion but to substantially prevent excess gas flow around the outside of the insert.

[0115] As described above, the tie bar cradle inserts 15, 151 of the tie bar assembly 101 are installed into the through-hole 7 in the block 100 so that corresponding mating features (e.g., slots, openings 16a, 154a) provided on the outer section by-pass the tab 8 on the inner surface 7a of the through-hole 7 of the block 100. The tie bar cradle insert 15, 151 is then rotated far enough, preferably about 90 degrees, to fully engage the tabs 8 within the grooves 16b, 154b and secure it in place (see, e.g., FIG. 19C). This defines a refractory block assembly 102 (FIG. 19C) or 103 (FIG. 19E). Another tie bar cradle insert is also installed in an opposite-facing block on an opposed (facing) portion of the tunnel wall (see, e.g., FIG. 27), so that tie bar cradle inserts 15, 151 are provided in matching locations on the inside faces of both tunnel walls, and then a tie bar 50 (FIG. 18) is installed into the cradle that has been created thereby to define the tie bar assembly 101 (including at least refractory block assemblies 102 and/or 103 and a tie bar 50; see FIGS. 20 and 27). It should be noted that anther refractory insert can be used in a different hole of the same block that is otherwise included in an assembly 102, 103 with the tie bar cradle insert member according to the present invention (see, e.g., FIG. 27, wherein a tie bar assembly 101 is then added to the same blocks 100 already defining refractory assemblies 104 (including blocks 100 and an insert 230; see also FIG. 26).

[0116] Tie bar cradle inserts 15, 151 can be installed in refractory blocks 100 and positioned at various locations along the tunnel walls when the tunnel walls are built, and then tie bars 50 can be readily added during installation, or later removed as needed without requiring substantial down time or creating deleterious maintenance issues. Once fully installed, this tie bar assembly 101 prevents the tunnel walls from moving horizontally in either direction (see FIGS. 27-29).

[0117] Flow Restricting/Constricting Plugs Refractory Insert Members (Plugs)

[0118] Another refractory insert according to the present invention is referred to as a flow restricting or flow constricting plug (hereinafter referred to simply as plugs, or refractory insert plugs). As shown in FIGS. 21A-F, the refractory insert plugs 130, 136, 230 and 330 are essentially refractory annular rings with openings of various sizes (see, e.g., FIGS. 21A-E) formed in the respective central portions thereof, or alternatively, solid pucks 430 (see, e.g., FIG. 21F). The refractory insert plugs are inserted into the through-holes 7 of the blocks 100, and which have corresponding mechanical mating features, such as openings/slots (FIGS. 21B, 21C) or openings/slots and grooves (FIG. 21A, 21D-21F) that by-pass and then mechanically engage the tabs 8 on the inner diameter 7a of the through-hole 7 in the block 100. The outer diameter of the refractory insert plug is slightly smaller than the inner diameter of the through-hole of the block to allow for proper insertion but to substantially prevent excess gas flow around the outside of the insert.

[0119] As shown in FIG. 21A, according to one aspect of the present invention, the refractory insert plug 130 has a central disc-shaped portion 131 with an opening 131a in the central portion thereof to permit gas flow. An annular rim (flange) 132 circumscribes the central portion 131 and defines a pair of opposed openings 132b (preferably around about 60 or more (at least slightly bigger than the tabs 8) and a groove (channel) 132a communicating therebetween. The groove (channel) 132a is dimensioned to receive and securely retain the tabs 8. The refractory insert plug 130 in FIG. 21A can be installed from either the inside or the outside of the tunnel by simply turning it sideways, inserting it so that the opening (slot) 132b will bypass the tabs 8 on the inner diameter 7a of the block 100 through-holes 7, and then rotating it far enough, preferably about 90, into place so that the tabs 8 then securely reside within the groove 132a. A refractory assembly 104 (including a block 100 having two refractory insert plugs 130 installed in the through-holes thereof) is shown in FIG. 26. An example of a refractory assembly 104 including half-block 1A with a refractory insert plug 130 installed in the through-hole thereof is also shown in FIG. 26.

[0120] FIG. 21D shows a refractory insert plug according to another aspect of the present invention. The refractory insert plug 230 has a central disc-shaped portion 231 with an opening 231a in the central portion thereof to permit gas flow. The opening 231a is larger than the opening 131a shown in FIG. 21A. An annular rim (flange) 232 circumscribes the central portion 231 and defines a pair of opposed openings 232b (preferably around about 60 or more (at least slightly bigger than the tabs 8) and a groove (channel) 232a communicating therebetween. The groove 232a is dimensioned to receive and securely retain the tabs 8. The refractory insert plug 230 in FIG. 21D can be installed from either the inside or the outside of the tunnel by simply turning it sideways, inserting it so that the opening (slot) 232b will bypass the tabs 8 on the inner diameter 7a of the block 100 through-holes 7, and then rotating it far enough, preferably about 90, into place so that the tabs 8 then securely reside within the groove 232a. A refractory assembly 104 (including a block 100 having a refractory insert plug 230 installed in at least one through-hole thereof) is shown in FIG. 26.

[0121] FIG. 21E shows a refractory insert plug according to another aspect of the present invention. The refractory insert plug 330 has a central disc-shaped portion 331 with an opening 331a in the central portion thereof to permit gas flow. The opening 331a is much smaller than the openings 131a and 231a shown in FIGS. 21A and 21D. An annular rim (flange) 332 circumscribes the central portion 331 and defines a pair of opposed openings 332b (preferably around about 60 or more (at least slightly bigger than the tabs 8) and a groove (channel) 332a communicating therebetween. The groove 332a is dimensioned to receive and securely retain the tabs 8. The refractory plug 330 in FIG. 21E can be installed from either the inside or the outside of the tunnel by simply turning it sideways, inserting it so that the opening (slot) 232b will bypass the tabs 8 on the inner diameter 7a of the block 100 through-holes 7, and then rotating it far enough, preferably about 90, into place so that the tabs 8 then securely reside within the groove 332a.

[0122] FIG. 21F shows a refractory insert plug according to another aspect of the present invention, also referred to as a puck. The refractory insert plug 430 has a solid central disc-shaped portion 431, without any openings formed therein, in order to restrict gas flow. An annular rim (flange) 432 circumscribes the central portion 431 and defines a pair of opposed openings 432b (preferably around about 60 or more (at least slightly bigger than the tabs 8) and a groove (channel) 432a communicating therebetween. The groove 432a is dimensioned to receive and securely retain the tabs 8. The plug 430 in FIG. 21D can be installed from either the inside or the outside of the tunnel by simply turning it sideways, inserting it so that the opening (slot) 432b will bypass the tabs 8 on the inner diameter 7a of the block 100 through-holes 7, and then rotating it far enough, preferably about 90, into place so that the tabs 8 then securely reside within the groove 432a.

[0123] The refractory block assembly 105 shown in FIG. 22B includes the flow directing cap insert member 140 installed in the block 100. Another flow directing cap insert 140, or a different type of refractory insert member, can be inserted in the other through-hole 7 to define a double assembly within the same block.

[0124] As shown in FIGS. 21B and 21C, according to another aspect of the present invention, the refractory insert plug 136 has a central disc-shaped portion 135 with an opening 135a in the central portion thereof to permit gas flow. An annular rim (flange) 134 circumscribes the central portion 135 and defines a pair of opposed openings 134b (preferably around about 60 or less with respect to the circumference of the puck and the through-hole 7). As shown in FIGS. 21B and 21C, refractory insert plugs 136 can be installed either from the outside of the tunnel, by simply sliding into place, or from inside the tunnel, by turning them sideways, inserting them so that the opening 134 bypasses the tabs 8 on the inner diameter 7a of the block 100 through-holes 7, and then pulling them back into place. The tab 8 will sit within the opening 134 and maintain proper orientation of the insert member. The refractory plugs 136 can be secured in place with either compressed high temperature fiber, or a thin bead of mortar.

[0125] The refractory block assembly 104 shown in FIGS. 21B and C includes the refractory insert plugs 136 installed in the block 100. A different refractory plug member, or an altogether different type of refractory insert member, can be substituted for one of the inserts 136 and inserted in the other through-hole 7 to define a different double assembly within the same block 100, or one of the inserts 136 can be removed to define a single assembly. As shown in FIGS. 25-29, refractory assemblies including one or more types of refractory plug members (e.g., 130, 230) in blocks 1A or 100 are referred to as refractory assemblies 104, 104 and 104.

[0126] As shown in FIG. 21F, when the central portion of the refractory insert plugs (430) is instead entirely solid (i.e., pucks), these refractory insert members serve to prevent any gas flow from passing through the respective through-hole 7 in the block 100. FIGS. 21A, 21D and 21E show embodiments of plugs as annular rings with central openings of various sizes, which dictate the amount of gas flow that will be permitted to enter the tunnel at that given location. It should be noted that these embodiments can be designed to be inserted and fixed in accordance with either method discussed above (i.e., the twist-lock method of FIGS. 21A and 21D-F, or the slide-in and fix method of FIGS. 21B, 21C).

[0127] Any of the refractory insert plugs according to the present invention can be removed and or replaced with another refractory insert plug having a different configuration (i.e., a different central ring size opening or a solid puck) after the original installation, if it is deemed necessary by the end user to alter the flow dynamics.

[0128] Flow Directing Cap Insert Member

[0129] Another refractory insert member according to the present invention is a flow directing cap 140 (FIGS. 22A and 22B). As shown, the flow directing cap 140 is a hollow, substantially cylindrical member 140 includes an open first end 140a, and opposed second end 140b (having an opening 140d) and a central cylindrical portion 140c. The outer diameter of the flow directing cap insert is slightly smaller than the inner diameter of the through-hole 7 of the block to allow for proper insertion but to substantially prevent excess gas flow around the outside of the insert. The outer peripheral surface of the first end 140a is provided with corresponding mechanical mating features (e.g., openings/slots 141a) that by-pass and mechanically engage with the tabs 8 on the inner diameter 7a of the through-hole 7 in the brick (block) 100 in the same manner as the tie bar cradle insert 15, 151 described above. Specifically, proximate the first end 140a is an annular flange 141 and a parallel annular flange 142 defining a groove or channel 143 therebetween. At least the flange 141 includes a pair of diametrically opposed openings (slots) 141a that are sized appropriately to allow the tabs 8 to pass therethrough. Preferably, the slots are around about 60 or more (at least slightly bigger than the tabs 8) with respect to the circumference of the flow directing cap insert 140 and the through-hole 7. The space (groove, channel) 143 between the parallel flanges 141 and 142 is dimensioned to accept securely retain the tabs 8 therein once the flow directing cap insert member 140 is rotated far enough, preferably about 90 degrees.

[0130] The second end 140b of the flow directing cap insert includes an annular lip and the opening 140d. A hooded, cup-like portion 144 is provided to obscure or otherwise cover a portion of the opening 140d so as to direct the gas flow exiting therefrom. The hooded, cup-like portion can be made to have any opening angle needed, as described, for example, in connection with U.S. Pat. No. 8,439,102, and/or insert members 140 having a single or mixed types of angle-openings can be arranged in through-holes at different locations to control the flow by changing the orientation of the hood opening/angle.

[0131] The refractory block assembly 105 shown in FIG. 22B includes the flow directing cap insert member 140 installed in the block 100. Another flow directing cap insert 140, or a different type of refractory insert member, can be inserted in the other through-hole 7 to define a double assembly within the same block.

[0132] In effect, the flow directing cap insert member 140 enables the flue gas that passes therethrough to be redirected in a specific direction, other than in a direct line with the through-hole of the block, as dictated by the needs of the end user, and can be placed in any location in the tunnel system that is needed to alter the flow dynamics.

The Tunnel Assembly (Also Referred to Interchangeably Herein as a Tunnel)

[0133] As shown in FIGS. 25-28, the tunnel assembly 200 includes a plurality of base components 30 are arranged to extend horizontally (in a first direction or the horizontal arrangement direction, i.e., defining a width of the tunnel) and are aligned with respect to one another to define a substantially continuous base surface along the longitudinal extension direction (length) of the tunnel. The base components 30 are secured to one another via the mechanical mating members 35, 36 (preferably without any mortar). A plurality of wall-forming blocks 10 are vertically stacked onto the base components 30 on both opposed sides, along the longitudinal extension direction of the tunnel, which helps further secure the base components 30 in place. The blocks 10 are arranged in a sequentially off-set manner, by one half of a length on the base components 30, using the respective mechanical mating members 33 (protruding portions from the base components 30) and 4 (openings on the blocks 10) to securely fasten the blocks 10 into place on the base components 30 without the use of mortar. The blocks 10 are also secured to one another via the respective mechanical mating members 5, 6. A plurality of blocks 1A, 100 are then stacked vertically and along the longitudinal extension direction on the row of blocks 10 in a similar, half-block off-set manner.

[0134] Additional blocks 1A, 100 are then alternately stacked onto one another, secured to one another vertically and horizontally, preferably without mortar, via the respective mechanical mating members 3, 4, 5 and 6, continuing in a half-block, off-set manner, to define two parallel, vertically oriented tunnel walls 8 that extend both in the second (i.e., vertical arrangement direction) from the base components 30 and in the longitudinal extension direction of the tunnel. As shown, some of the blocks correspond to the blocks 10 shown in FIG. 11 (without through-holes 7), and some of the blocks correspond to the blocks 100 shown in FIG. 16, which include through-holes 7. Blocks 1A are otherwise the same as those shown and described as blocks 1 in FIG. 10, with the exception of the though-hole that is included in blocks 1A.

[0135] The tunnel walls 8 are spaced a predetermined distance (i.e., 12-60 in, preferably 24 to 36 in) apart from one another in the horizontal arrangement direction, dictated by the horizontal span of the base components 30. Tie bars 50 are inserted into refractory insert members (tie bar cradles 15 or 151) in desired locations, as needed. Other refractory insert members, such as refractory plug inserts 130, 136, 230, 330, or 430, and flow directing cap insert members 140 can also be inserted into the through-holes 7 of the blocks 100 in the any location that is desired to define refractory block assemblies at those points (see, e.g., FIG. 26). The tunnel assembly is secured by placing a plurality of lids 60 across the tops of the tunnel walls 8, which are secured in place onto the uppermost blocks 10 via the mechanical mating features (e.g., openings 64 in the lids and the protruding portions 3 of the wall blocks 10), and further secured to one another via the mechanical mating members 65, 66 in the lids 60 to construct the tunnel 200 (also referred to as a tunnel assembly 200 or 200A, see, e.g., FIGS. 25-29).

[0136] As discussed above, in the tunnel 200 according to the present invention, reducing the weight of all of the components, while maintaining the structural integrity of each of the individual components, makes it possible to eliminate much of the crushing force on the lower courses of the brick (i.e., the base components 30). Providing light-weight, structurally correct cover (lid) components 60 overcomes the drawbacks previously associated with making conventional lids thicker in order to be stronger, which also detrimentally added additional load to the entire system. The incorporation of controlled expansion gaps between each brick and elimination of mortar from the overall system ensures that the tunnel assembly 200 can expand and contract without creating large cumulative stresses, and reduces the installation time of the tunnel assembly 200, 200A as a whole.

[0137] With the reduced wall thickness and improved materials used for the components, the light-weight tunnel lids 60 can be easily installed or removed simply by two laborers. In addition, the light-weight, mortar-free blocks with interlocking mechanical mating features are easily handled by a single laborer, and the tunnel structure 200 can assembled, repaired and/or disassembled as necessary without significant consequences or the requirement for high levels of skill. Cross beam supports (i.e., tie bars 50 in respective cradle inserts), as well as other refractory insert members, such as flow restricting/constricting plugs and flow directing caps, can be easily added or removed from the blocks (block assemblies) in the tunnel assembly 200 without limiting access to other tunnel components during turnarounds, ensuring that repairs can be complete and effective. Faster installation and repair time also allows for proper repairs to be made more readily, improving the overall reliability of the system.

[0138] FIGS. 26 and 27 best illustrate an example of a tunnel 200 including a combination of different blocks 1A, 10 and 100 and defining a number of different refractory assemblies (e.g., 104, 104, 104 and 102). Although this embodiment does not depict a flow directing cap insert member, any of the various refractory inserts according to the present invention can be used in conjunction with any through-hole location in any of the blocks of the tunnel system to define a refractory block assembly within the tunnel assembly, thereby providing a modular system that allows for a universal refractory insert-mating tab to be provided on the surface of the openings of the blocks that are be used in conjunction with any insert in any location in the tunnel. This vast flexibility enables the end user to modify the installation of refractory insert members in any manner that they deem necessary depending on the particular processing conditions and requirements that they face.

[0139] While the present invention has been shown and described above with reference to specific examples, it should be understood by those skilled in the art that the present invention is in no way limited to these examples, and that variations and modifications can readily be made thereto without departing from the scope and spirit of the present invention.