COKE OVEN CORBEL STRUCTURES

Abstract

Coke oven corbel structures include an assembly of multiple stacked tiers of refractory blocks defining a plurality of substantially vertically oriented central flues. A first tier of refractory blocks in the assembly includes a series of lower cradle blocks defining respective lower semi-circular surfaces extending from one end to another end of the corbel structure. A second tier of the refractory blocks in the assembly includes a series of upper crown blocks defining respective upper semi-circular surfaces extending from one end to another end of the corbel structure. At least one set of the upper crown blocks in the second tier of refractory blocks defines respective substantially vertical segments of the vertically oriented central flues of the corbel structure which is in fluid communication with a cylindrical channel of the corbel structure.

Description

FIELD

The embodiments disclosed herein relate generally to coke ovens, especially corbel structures associated with coke ovens. In preferred embodiments, the corbel structures disclosed herein are formed of an assembly of monolithic refractory blocks.

BACKGROUND

Coke ovens traditionally comprise massive refractory brick structures in which there are batteries of adjacent parallel walls made up from a large variety of differently shaped refractory bricks. The bricks must be able to withstand high temperatures and strong mechanical loading. At the same time, the interior of the walls contains flue ducts, burners, flue gas control passages and the like. The detailed design of the oven is usually quite complicated in order to obtain the necessary heat distribution within the oven and gas flows through the walls.

It follows from the above that coke ovens are relatively costly structures and any downtime for servicing and repairs can represent a significant economic loss for an operator.

Further, the production of ceramic bricks from which the walls are made is relatively costly and there is accordingly a need to generally reduce the number of different types of bricks which are used in a wall. It is undesirable, however, to have a design concept which utilizes relatively large ceramic bricks in the construction. Excessively large bricks cannot be handled without the use of specialized mechanical lifting devices. Further, bricks having a dimension greater than 650 mm machine pressed to form a fused silica product are generally unavailable. Bricks greater than this size can be hand cast but these are much more expensive. Large bricks can be machine pressed from conventional silica, but conventional silica bricks would have a very serious disadvantage in that a wall made therefrom would need a heat-up time which is many times greater than that for fused silica bricks.

U.S. Pat. Nos. 6,066,236, 8,266,853 and 8,640,635 (the entire content of each such patent being expressly incorporated hereinto be reference) have proposed that relatively large-sized monolithic refractory blocks may be assembled to form the corbel structures of coke ovens. In general, the assembly of such large-sized monolithic refractory blocks enables the coke ovens to be constructed and/or repaired with much less production down time.

While such prior proposals for coke oven corbel structures are satisfactory for their intended purpose, continual improvements are sought. It is towards providing such improvements that the embodiments disclosed herein are directed.

SUMMARY

The coke oven corbel structures of the embodiments disclosed herein include an assembly of multiple stacked tiers of refractory blocks defining a plurality of substantially vertically oriented central flues. A first tier of refractory blocks in the assembly includes a series of lower cradle blocks defining respective lower semi-circular surfaces extending from one end to another end of the corbel structure. A second tier of the refractory blocks in the assembly includes a series of upper crown blocks defining respective upper semi-circular surfaces extending from one end to another end of the corbel structure.

The second tier of refractory blocks is stacked on the first tier of refractory blocks so that the respective upper and lower semi-circular surfaces of the upper crown blocks and lower cradle blocks thereof oppose one another to thereby define a cylindrical channel between opposed ends of the corbel structure. At least one set of the upper crown blocks in the second tier of refractory blocks defines respective substantially vertical segments of the vertically oriented central flues of the corbel structure, a lower end of the substantially vertical segments terminating at the upper semi-circular surface to thereby be in fluid communication with the cylindrical channel of the corbel structure.

According to certain embodiments, upper and lower end blocks may be provided at least at the one end of the corbel structure, wherein the upper and lower end blocks define opposed upper and lower rectangular U-shaped cradle surfaces. A transition gun block may thus be received within the U-shaped cradle surfaces of the upper and lower end blocks, in which case the transition gun block defines a gun block transition channel in fluid communication with the cylindrical channel defined by the upper and lower cradle blocks. The transition gun block may be in the form of a rectangular cuboid. Alternatively or additionally, the transition gun block may include upper and lower gun block sections defining opposed U-shaped surfaces to establish the gun block transition channel.

Some embodiments of the corbel structure may include at least a second set of the upper crown blocks in the second tier of refractory blocks which defines respective diagonally oriented lateral flue segments of diagonally oriented lateral flues of the corbel structure. If present, the first and second sets of the upper crown blocks are positioned alternately adjacent to one another.

A third tier of refractory blocks may be provided according to other embodiments, whereby the refractory blocks of the third tier are stacked on the second tier of refractory blocks. If present, the third tier of refractory blocks may comprise a series of inverted T-shaped flue blocks. The inverted T-shaped flue blocks may be provided with upper and lower ledge surfaces. Lower spacer blocks having respective ends supported by the lower edges of the inverted T-shaped flue blocks may thus be provided in the third tier of refractory blocks.

Some embodiments will include at least one set of the inverted T-shaped blocks in the third tier of refractory blocks which defines respective substantially vertical segments of the vertically oriented central flues of the corbel structure. A lower end of the substantially vertical segments may thus be aligned with an upper end of the substantially vertical segments of upper cradle blocks so as to be in fluid communication therewith. The substantially vertical segments of the at least one series of inverted T-shaped blocks may be U-shaped. The U-shaped substantially vertical segments according to such embodiments would thereby have an open end closed by a vertical face of an adjacent one of the inverted T-shaped blocks.

According to other embodiments, at least a second set of the inverted T-shaped blocks in the third tier of refractory blocks defines respective diagonally oriented lateral flue segments of diagonally oriented lateral flues of the corbel structure.

Certain embodiments of the corbel structure will include a fourth tier of refractory blocks comprised of a series of elongate shoulder blocks positioned in an end-to-end manner on upper ledge surfaces of the inverted T-shaped blocks of the third tier. Upper spacer blocks may thus be positioned adjacent to the shoulder blocks and stacked on the lower spacer blocks.

According to some embodiments, a series of split cylindrical gun blocks may be positioned in the cylindrical channel of the corbel structure. The cylindrical gun blocks may comprise upper and lower semi-cylindrical gun block sections. Some embodiments will include an aperture defined by at least some of the upper semi-cylindrical gun block sections which is in fluid communication with respective ones of the substantially vertical segments of the at least one set of the upper crown blocks.

These and other aspects and advantages of the present invention will become more clear after careful consideration is given to the following detailed description of the preferred exemplary embodiments thereof.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS

The disclosed embodiments of the present invention will be better and more completely understood by referring to the following detailed description of exemplary non-limiting illustrative embodiments in conjunction with the drawings of which:

FIG. 1 is a perspective view showing an exemplary corbel structure in accordance with an embodiment of the present invention supported on a coke oven pier;

FIG. 2 is a perspective view showing just the corbel structure depicted in FIG. 1;

FIG. 3 is a top plan view of the corbel structure shown in FIG. 2;

FIG. 4 is a latitudinal cross-sectional elevational view of the corbel structure shown in FIG. 2 as taken along lines 4-4 in FIG. 2;

FIG. 5 is side elevational view of the corbel structure depicted in FIG. 2;

FIG. 6 is an end elevational view of the corbel structure depicted in FIG. 2;

FIG. 7 is a longitudinal cross-sectional view of the corbel structure depicted in FIG. 2 as taken along line 7-7 in FIG. 6;

FIG. 8 is an exploded view of the corbel structure depicted in FIG. 2 showing the individual tiers forming the same;

FIG. 9A is a perspective view of the first tier of blocks forming the corbel structure depicted in FIG. 2;

FIG. 9B is a perspective view similar to FIG. 9A but showing the transition gun block in an exploded position;

FIG. 10A is perspective a view of the second tier of blocks forming the corbel structure depicted in FIG. 2;

FIG. 10B is a perspective view similar to FIG. 10A but showing the lateral front shelf blocks in an exploded position;

FIG. 11 is a perspective view partly exploded of the third tier of blocks forming the corbel structure depicted in FIG. 2;

FIG. 12 is a perspective view of the fourth tier of blocks forming the corbel structure depicted in FIG. 2;

FIG. 13 is a perspective view of another embodiment of a corbel structure according to the invention;

FIG. 14 is a top plan view of the corbel structure depicted in FIG. 13;

FIG. 15 is an end elevational view of the corbel structure depicted in FIG. 13;

FIG. 16 is a longitudinal cross-sectional view of the corbel structure depicted in FIG. 13 as taken along line 17-17 in FIG. 15; and

FIG. 17 is an exploded view showing the tiers of blocks forming the corbel structure depicted in FIG. 13.

DETAILED DESCRIPTION

Accompanying FIG. 1 shows an exemplary corbel structure 10 in accordance with an embodiment of the present invention supported on a pier P associated with a coke oven battery. In this regard, it will be understood that a conventional coke oven battery will include a number of spaced apart piers P, each supporting a corbel structure 10 and defining therebetween regenerator regions provided with checker bricks (not shown). The corbel structures 10 in turn support the refractory walls and floors of the individual coke ovens (not shown).

FIGS. 2-12 show in greater detail the components of the corbel structure 10. In this regard it will be observed that the corbel structure 10 is comprised of essentially four courses 100, 200, 300 and 400 assembled from especially configured refractory blocks (to be described in greater detail below) which are stacked one on top of another. The courses 100, 200, 300 and 400 collectively define central substantially vertically oriented flues 60 and lateral substantially diagonally oriented flues 72 which communicate with corresponding flues within the walls of the coke oven walls (not shown) to allow for the burning of air and gas therein and the transport of heated waste gas to and from the regenerator regions.

FIGS. 9A and 9B are perspective assembled views of the interconnected refractory blocks forming the first tier 100 of the corbel structure 10, with FIG. 9B showing the transition gun block in an exploded position as compared to FIG. 9A. As shown, the first tier 100 of the corbel structure 10 is provided with an interconnected series of cradle blocks 102 each defining a semi-cylindrical surface 104 extending longitudinally between the front and rear faces of each block. When a series of the cradle blocks 102 are aligned within one another, the semi-cylindrical surface 104 will therefore define a longitudinal U-shaped channel extending in a lengthwise direction of the corbel structure 10.

An end block 106 is provided adjacent to a front face of the end-most one of the cradle blocks 102. The end block 106 defines a rectangular U-shaped cradle 106a for supporting a rectangular cuboid transition gun block 108 comprised of upper and lower gun block sections 108a, 108b. The gun block sections 108a, 108b define respective opposed semi-cylindrical surfaces which collectively establish a cylindrical channel 108c coaxially aligned with the U-shaped channel formed by the semi-cylindrical surfaces 104 of the cradle blocks 102.

The second tier 200 of blocks comprising the corbel structure 10 is shown in FIGS. 10A and 10B. As depicted, the second tier 200 is comprised of an alternating series of lateral flue crown blocks 202 and central flue crown blocks 204, the former defining a section of the diagonally oriented flues 72 and the latter defining a section of the substantially vertically oriented flues 60. More specifically, the central flue blocks 204 define a substantially vertically oriented rectangular segment of the flue 60, whereas the lateral flue crown blocks 202 define a diagonally oriented U-shaped channel which is closed by a vertical face of an adjacent one of the blocks 204. The central flue blocks 204 may include a static gas nozzle 207 positioned in the segment of the flue 60 so as to control the flow of gas thereinto.

An end block 206 is provided adjacent to a front face of the end-most one of the crown blocks 202. The end block 206 is provided with an inverted rectangular U-shaped cradle surface 206a to receive the upper gun block section 108a of the transition gun block 108. In addition, the end block 206 includes oppositely oriented mounting tongues 206b so as to mate with corresponding channel surfaces 208a associated with the wing blocks 208. In this regard, it will be observed that the lateral wing blocks 208 are each horizontally split to form upper and lower wing block segments 208b, 208c, the latter having a U-shaped channel 208d which is closed by an opposed face of the upper wing block segment 208b.

The third tier 300 of blocks forming the corbel structure 10 is depicted in FIG. 11. As shown the third tier 300 is comprised of an alternating series of inverted T-shaped lateral flue blocks 302 and inverted T-shaped central flue blocks 304, the former defining a section of the substantially vertically oriented flues 60 and the latter defining a section of the diagonally oriented flues 72. Lower spacer blocks 306 abut laterally against the side edges of the blocks 302, 304 and are supported by the upper lateral surfaces of the crown blocks 202, 204 of the subjacent second tier 200 of blocks. The blocks 302, 304 respectively define lower ledges 302a, 304a which are coplanar with the top surface of the lower spacer blocks 306. The upper spacer blocks 308 are thus supported by the lower spacer blocks 306 and have end portions which are received on the respective lower ledges 302a, 304a.

An inverted T-shaped end block 306 is provided adjacent to a front face of the end-most one of the blocks 304. The end block 306 defines a ledge 306a which is coplanar with the ledges 302a, 304a of the blocks 302, 304, respectively.

The fourth tier 400 of blocks forming the corbel structure 10 is depicted in FIG. 12. The fourth tier 400 includes a series of elongate shoulder blocks 402 positioned in an end-to-end manner on the upper ledge surfaces 302b, 304b of the blocks 302, 304, respectively, of the third tier 300 (see FIG. 11). A T-shaped end block 406 is positioned on the top surface of the end block 306 of the third tier 300. Spacer blocks 406 are laid onto the spacer blocks 308 of the third tier 300 in an abutting manner to the lateral surface of the blocks 402.

Another embodiment of a corbel structure 500 is shown in FIGS. 13-17. As is shown, the corbel structure 500 includes three tiers 600, 700 and 800 of blocks to be described in greater detail below. The courses 600, 700, and 800 collectively define central substantially vertically oriented flues 160 and lateral substantially diagonally oriented flues 172 which communicate with corresponding flues within the walls of the coke oven walls (not shown) to allow for the burning of air and gas therein and the transport of heated waste gas to and from the regenerator regions.

As is perhaps better shown in FIG. 17, the first tier 600 of the corbel structure 500 is provided with an interconnected series of cradle blocks 602 that are somewhat similar to the cradle blocks 102 of the corbel structure 10 as previously described. Each of the cradle blocks 602 defines a semi-cylindrical surface 604 extending longitudinally between the front and rear faces of each block. When a series of the cradle blocks 602 are aligned within one another, therefore, the semi-cylindrical surfaces 604 will therefore define a longitudinal U-shaped channel extending in a lengthwise direction of the corbel structure 500.

A series of split cylindrical gun blocks 606 comprised of an upper semi-cylindrical gun block 606a and a lower semi-cylindrical gun block 606b are positioned end-to-end relative to one another so that the lower semi-cylindrical gun blocks 606b are received by a respective semi-cylindrical surface 604 of the cradle blocks 602. At least some of the upper semi-cylindrical gun blocks 606a include apertures 606c which fluid-communicate with the substantially vertically oriented flues 160. Therefore, when assembled in an end-to-end manner, the split cylindrical gun blocks 606 will establish an elongate cylindrical passageway 607 which extends longitudinally through the corbel structure 500.

The second tier 700 is comprised of a series of an alternating series of lateral flue crown blocks 702 and central flue crown blocks 704, the former defining a section of the diagonally oriented flues 172, and the latter defining a section of the substantially vertically oriented flues 160. More specifically, the central flue crown blocks 704 define a substantially vertically oriented rectangular segment of the flue 160, whereas the lateral flue crown blocks 702 define a diagonally oriented U-shaped channel which is closed by a vertical face of an adjacent one of the blocks 204 (see FIG. 17). The segments of the flue 160 defined by the crown blocks 704 are aligned with respective apertures 606c formed in the upper semi-cylindrical gun blocks 606a. Non-apertured filler blocks 706 may be provided as needed (i.e., where it is not required to provide a section of the flues 160 and/or 172).

The crown blocks 702, 704 collectively define a semi-cylindrical surface 708 which conformably mates with the semi-cylindrical gun blocks 606a. The gun blocks 606 are thereby positionally captured between the crown blocks 702, 704 on the one hand and the cradle blocks 602 on the other hand. The crown blocks 704 may include a static gas nozzle 807 positioned in the segment of the flue 160 so as to control the flow of gas thereinto.

The third tier 800 is comprised of an alternating series of inverted T-shaped lateral flue cap blocks 802 and inverted T-shaped central flue cap blocks 804, the former defining a section of the substantially vertically oriented flues 160 and the latter defining a section of the diagonally oriented flues 172. Lower spacer blocks 806 abut laterally against the side edges of the blocks 802, 804 and are supported by the upper lateral surfaces of the blocks 702, 704 of the subjacent second tier 700 of blocks. The blocks 802, 804 respectively define lower ledges 802a, 804a which are coplanar with the top surface of the lower spacer blocks 806. The upper spacer blocks 808 (see FIGS. 13-15) are thus supported by the lower spacer blocks 806 and have respective end portions which are received on the lower ledges 802a, 804a. Similarly configured non-apertured filler blocks 810 may be provided as needed (i.e., where a segment of the flues 160, 172 is not required).

A series of elongate shoulder blocks 812 is positioned in an end-to-end manner on the upper ledge surfaces 802b, 804b of the blocks 302, 304, respectively, of the third tier 300 (see FIG. 11). Spacer blocks 814 are laid onto the spacer blocks 808 in an abutting manner to the lateral surface of the blocks 812.

The various blocks as described above which comprise the corbel structures 10 and 500 are preferably provided with interlocking tongue and groove structures such as described in U.S. Provisional Patent Application Ser. No. 62/082,922.

It will be understood that the description provided herein is presently considered to be the most practical and preferred embodiments of the invention. Thus, the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope thereof.

Claims

1. A corbel structure for a coke over comprising: an assembly of multiple stacked tiers of refractory blocks defining a plurality of substantially vertically oriented central flues, whereina first tier of refractory blocks in the assembly includes a series of lower cradle blocks defining respective lower semi-circular surfaces extending from one end to another end of the corbel structure, and whereina second tier of the refractory blocks in the assembly includes a series of upper crown blocks defining respective upper semi-circular surfaces extending from one end to another end of the corbel structure, and whereinthe second tier of refractory blocks is stacked on the first tier of refractory blocks so that the respective upper and lower semi-circular surfaces of the upper crown blocks and lower cradle blocks thereof oppose one another to thereby define a cylindrical channel between opposed ends of the corbel structure, and whereinat least one set of the upper crown blocks in the second tier of refractory blocks defines respective substantially vertical segments of the vertically oriented central flues of the corbel structure, a lower end of the substantially vertical segments terminating at the upper semi-circular surface to thereby be in fluid communication with the cylindrical channel of the corbel structure.

2. The corbel structure according to claim 1, further comprising upper and lower end blocks at least at the one end of the corbel structure, wherein the upper and lower end blocks define opposed upper and lower rectangular U-shaped cradle surfaces.

3. The corbel structure according to claim 2, further comprising a transition gun block received within the U-shaped cradle surfaces of the upper and lower end blocks, wherein the transition gun block defines a gun block transition channel in fluid communication with the cylindrical channel defined by the upper and lower cradle blocks.

4. The corbel structure according to claim 3, wherein the transition gun block is a rectangular cuboid.

5. The corbel structure according to claim 3, wherein the transition gun block includes upper and lower gun block sections defining opposed U-shaped surfaces to establish the gun block transition channel.

6. The corbel structure according to claim 1, wherein at least a second set of the upper crown blocks in the second tier of refractory blocks defines respective diagonally oriented lateral flue segments of diagonally oriented lateral flues of the corbel structure.

7. The corbel structure according to claim 6, wherein the first and second sets of the upper crown blocks are positioned alternately adjacent to one another.

8. The corbel structure according to claim 1, further comprising a third tier of refractory blocks stacked on the second tier of refractory blocks, wherein the third tier of refractory blocks comprises a series of inverted T-shaped flue blocks.

9. The corbel structure according to claim 8, wherein the inverted T-shaped flue blocks include upper and lower ledge surfaces.

10. The corbel structure according to claim 9, further comprising lower spacer blocks having respective ends supported by the lower edges of the inverted T-shaped flue blocks.

11. The corbel structure according to claim 8, wherein at least one set of the inverted T-shaped blocks in the third tier of refractory blocks defines respective substantially vertical segments of the vertically oriented central flues of the corbel structure, a lower end of the substantially vertical segments being aligned with an upper end of the substantially vertical segments of upper cradle blocks so as to be in fluid communication therewith.

12. The corbel structure according to claim 11, wherein the substantially vertical segments of the at least one series of inverted T-shaped blocks is U-shaped having an open end closed by a vertical face of an adjacent one of the inverted T-shaped blocks.

13. The corbel structure according to claim at least a second set of the inverted T-shaped blocks in the third tier of refractory blocks defines respective diagonally oriented lateral flue segments of diagonally oriented lateral flues of the corbel structure.

14. The corbel structure according to claim 10, further comprising a fourth tier of refractory blocks comprised of a series of elongate shoulder blocks positioned in an end-to-end manner on the upper ledge surfaces of the inverted T-shaped blocks.

15. The corbel structure according to claim 14, comprising upper spacer blocks positioned adjacent to the shoulder blocks and stacked on the lower spacer blocks.

16. The corbel structure according to claim 1, further comprising a series of split cylindrical gun blocks positioned in the cylindrical channel of the corbel structure.

17. The corbel structure according to claim 16, wherein the cylindrical gun blocks comprising upper and lower semi-cylindrical gun block sections, wherein at least some of the upper semi-cylindrical gun block sections define an aperture in fluid communication with respective ones of the substantially vertical segments of the at least one set of the upper crown blocks.