Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D1/0003—Linings or walls
  • F27D1/0006—Linings or walls formed from bricks or layers with a particular composition or specific characteristics
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
  • F27B14/00—Crucible or pot furnaces
  • F27B14/06—Crucible or pot furnaces heated electrically, e.g. induction crucible furnaces with or without any other source of heat
  • F27B14/061—Induction furnaces
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
  • F27B14/00—Crucible or pot furnaces
  • F27B14/08—Details specially adapted for crucible or pot furnaces
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
  • F27B14/00—Crucible or pot furnaces
  • F27B14/08—Details specially adapted for crucible or pot furnaces
  • F27B14/10—Crucibles
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D1/02—Crowns; Roofs
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D1/04—Casings; Linings; Walls; Roofs characterised by the form, e.g. shape of the bricks or blocks used
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D1/10—Monolithic linings; Supports therefor
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D1/14—Supports for linings
  • F27D1/145—Assembling elements
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
  • F27B14/00—Crucible or pot furnaces
  • F27B14/06—Crucible or pot furnaces heated electrically, e.g. induction crucible furnaces with or without any other source of heat
  • F27B14/061—Induction furnaces
  • F27B2014/066—Construction of the induction furnace
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
  • F27B14/00—Crucible or pot furnaces
  • F27B14/08—Details specially adapted for crucible or pot furnaces
  • F27B2014/0843—Lining or casing
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
  • F27B14/00—Crucible or pot furnaces
  • F27B14/08—Details specially adapted for crucible or pot furnaces
  • F27B14/10—Crucibles
  • F27B2014/104—Crucible linings
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D2001/0046—Means to facilitate repair or replacement or prevent quick wearing
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D2001/0046—Means to facilitate repair or replacement or prevent quick wearing
  • F27D2001/005—Removable part or structure with replaceable elements
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D2001/0046—Means to facilitate repair or replacement or prevent quick wearing
  • F27D2001/0053—Furnace constructed in modules
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D2001/0059—Construction elements of a furnace
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D2001/0059—Construction elements of a furnace
  • F27D2001/0066—Movable or removable parts

Definitions

• the present invention relates to a precast ring for use in a furnace, a refractory lining comprising a precast ring and a dry vibration material and a method of forming a refractory lining.
• a range of refractory linings are known that are used in the operation of furnaces.
• the refractory linings are required to be mechanically stable and resistant to the harsh conditions in a furnace. This poses many challenges including maintaining the integrity of the refractory lining throughout the furnace for effective and safe operation. For example, it is often the case that the refractory lining towards the top of the furnace has a lower strength and can crumble or crack. This not only requires the lining to be repaired and/or replaced frequently, but such defects in the factory lining can also be unsafe and can even lead to explosions.
• a precast ring (1) wherein the ring (1) comprises a protrusion (2) on the bottom surface of the ring (3) for use in a furnace.
• a refractory lining comprising a precast ring (1) according to the first aspect and a dry vibration material.
• a method of forming a refractory lining according to the second aspect comprising:
• a precast ring according to the first aspect as refractory lining.
• kits comprising a precast ring according to the first aspect and a dry vibration material.
• the present invention is based on the surprising finding that the use of a precast ring can improve the safety and usability of furnaces.
• the present invention can provide many benefits to the operation of furnaces, in particular electric furnaces, such as a core induction furnace (CIF). These operational benefits are evident when the furnace with a range of refractory linings, such as refractory linings comprising a dry vibration material (DVM).
• CIF core induction furnace
• DVM dry vibration material
• the precast ring according to the invention can be manufactured off site and subsequently installed in the furnace on site. An improvement of efficiency when operating furnaces can be observed by using this route.
• the precast ring can be prefabricated, delivered to site and installed in the furnace by vibrating the ring with the DVM composition.
• the precast ring can be made to order according to the dimensions of a specific furnace.
• the method of installation described herein may form a seamless, or near seamless, joint in the refractory lining contributing to a refractory lining with good mechanical properties.
• a seamless, or near seamless, joint according to the invention helps prevent leakage before, during and/or after the furnace is operation. This may also contribute to the increasing the safety of operating the furnace.
• the precast ring can be used in a range of furnaces, such as coreless induction furnaces.
• the precast ring comprises a protruding portion on the bottom surface of the ring.
• the protrusion is an integral part of the precast ring and forms a thinner edge away from the ring (see e.g. Fig 2 ).
• the protruding portion may be a one or more ridges, tapered portions and/or projecting portions.
• a protruding portion of this shape can be utilised to form part of a refractory lining in combination with a refractory material such as DVM.
• the protruding portion can form an airtight bond with the DVM to form the refractory lining.
• the precast ring can form the upper part of the refractory lining that is in close proximity to the lid of the furnace.
• the use of a precast ring in this position may improve the overall strength of the refractory lining, especially as this part of the furnace is often prone to weaknesses in the refractory lining using known methods. Any increase in overall strength of the refractory lining leads to an improvement in the safety of operating the furnace.
• the top part of the precast ring may comprise at least one recessed portion, such as two recessed portions or three recessed portions, whereby a section of the ring is absent, recessed, indented and/or cut out.
• the at least one recessed portion may be any shape, such as rectangular or circular.
• Such recessed portions can be tailored to a particular furnace to allow the furnace to freely function. For example, a recessed portion can allow space for the spout of the furnace. In some examples, the recessed portions may be flush with the one or more spout(s) of the furnace.
• the at least one recessed portion is at least partially chamfered, such as stepped or tiered.
• the recessed portion may be slanted. Without wishing to be bound by theory, it is considered that the shape of the recessed portion in this way helps avoid leakage out of the furnace and therefore contributes to the overall safety of operating the furnace.
• the top surface of the ring comprises two or more attachment units.
• the top surface of the ring may comprise three attachments units, or four attachments units, or five attachments units, or six attachments units, or seven attachment units.
• the attached units may be, for example, hooks or eyelets.
• the attachment units may be utilised to lower the ring into the furnace. The number of attachment units required is expected to be greater for larger structures. In some examples, a minimum of three attachments units are required to securely lower the ring into the furnace.
• the precast ring has an inner diameter of from about 0.5 m (meters) to about 4.0 m (meters), for example from about 0.6 m to about 3.8 m, or from about 0.8 m to about 3.6 m, or from about 1.0 m to about 3.4 m, or from about 1.2 m to about 3.2 m, or from about 1.4 m to about 3.0 m, or from about 1.6 m to about 2.8 m, or from about 1.8 m to about 2.6 m, or from about 2.0 m to about 2.4 m.
• the precast ring has a total height from the bottom surface of the ring to the top surface of the ring of from about 300 mm to about 1500 mm, for example, from about 350 mm to about 1450 mm, or from about 400 mm to about 1400 mm, or from about 500 mm to about 1300 mm, or from about 600 mm to about 1200 mm, or from about 700 mm to about 1000 mm, or from about 800 mm to about 900 mm.
• the precast ring has a recessed portion with a height of from about 50 mm to about 1450 mm, for example, from about 100 mm to about 1400 mm, or from about 150 mm to about 1300 mm, or from about 200 mm to about 1200 mm, or from about 300 mm to about 1100 mm, or from about 400 mm to about 1000 mm, or from about 500 mm to about 800 mm, or from about 600 mm to about 700 mm.
• the precast ring comprises the refractory material in an amount of at least about 70 wt.% based on the total weight of the precast ring, for example, at least about 75 wt.%, or at least about 80 wt.%, or at least about 85 wt.%, or at least about 90 wt.%, or at least about 95 wt.%, or at least about 98%, or at least about 99 wt.%, based on the total weight of the precast ring.
• the precast ring comprises the fibres in an amount of at least about 30 wt.% based on the total weight of the precast ring, for example, at least about 25 wt.%, or at least about 20 wt.%, or at least about 15 wt.%, or at least about 10 wt.%, or at least about 5 wt.%, or at least about 2%, or at least about 1 wt.%, based on the total weight of the precast ring.
• the top section of the precast ring comprises more fibres than the bottom section of the precast ring.
• the fibres are selected from metal fibres, mineral fibres and/or plastic fibres.
• the metal fibres comprise steel and/or tungsten.
• the precast ring has a smooth surface.
• a smooth surface can have operational advantages, such as the reduction is unwanted material such as slag sticking to the surface.
• a refractory lining according to the present disclosure may comprise a precast ring and a DVM.
• the DVM is boron free. Any known DVM can be used with the precast ring to form a refractory lining.
• the precast ring makes up between about 15% to about 30% of the of the total height of the furnace wall.
• the precast ring makes up about 20%, or up to about 22 %, or up to about 25% or up to about 28% the height of the furnace wall.
• a method of forming a refractory may comprise driving the precast ring into the DVM refractory wall by about between about 10 mm to 80 mm.
• the precast ring may be driven into the DVM by about 15 mm, or about 20 mm, or about 25 mm, or about 30 mm, or about 35 mm, or about 40 mm, or about 45 mm, or about 50 mm, or about 55 mm, or about 60 mm, or about 65 mm, or about 70 mm, or about 75 mm.
• the dry vibration material composition used in the method has not been sintered and may be a loose material that this able to move freely and can fill up any gaps that are present.
• This dry vibration material composition is then compacted by vibration as part of the method according to the invention. Once compacted and sintered, the dry vibration material composition is no longer a loose, free flowing material.
• the method causes the precast ring to be driven into the dry vibration material. This can occur by gravitational forces, aided by the vibration and/or pushed down mechanically.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Furnace Housings, Linings, Walls, And Ceilings (AREA)

Priority Applications (2)

Applications Claiming Priority (1)

Publications (1)

Family

ID=91432971

Family Applications (1)

Country Status (2)

Citations (4)

• 2024
  • 2024-05-24 EP EP24305828.6A patent/EP4653791A1/fr active Pending
• 2025
  • 2025-05-23 WO PCT/EP2025/064410 patent/WO2025242920A1/fr active Pending

Patent Citations (4)

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