COKE OVEN WALL STRUCTURE AND COMPONENT BLOCKS THEREOF

Abstract

Coke oven wall structures are provided with a pair of interconnected opposed first and second block components, each of which is generally an asymmetrical T-shaped unitary structure having an interior wall element integrally formed at substantially a right angle to a side wall element. The interior wall element of each of the first and second block components includes a terminal end defining reverse mirror images of respective L-shaped notches which establish corresponding protruding finger elements. In such a manner, each of the protruding finger elements of the first and second block components is received within the L-shaped recesses of the second and first block components, respectively, when such components are positioned in opposition to one another.

Description

FIELD

The embodiments disclosed herein relate generally to coke oven wall structures and methods of making the same.

BACKGROUND

Coke ovens traditionally comprise massive refractory brick structures in which there are batteries of adjacent parallel walls constructed 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 regions of the walls contain 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 wall 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

In general, the embodiments disclosed herein are directed toward coke oven wall structures associated with coke ovens and component blocks thereof. According to certain embodiments, the coke oven wall structure will comprise series of end-to-end interconnected blocks laid in alternating stacked courses defining opposed faces of the wall structure and internal flue openings. Each of the interconnected blocks may comprise a pair of interconnected opposed first and second block components, where the first and second block components are generally a T-shaped unitary structure having an interior wall element which is integrally formed at substantially a right angle to a side wall element, the interior wall element extending inwardly relative to the opposed faces of the wall structure.

The interior wall element may be asymmetrically offset relative to a transverse centerline of the first and second block components so as to establish shorter and longer side wall elements thereof. The interior wall element of each of the first and second block components includes a terminal end defining an L-shaped notch which establishes a corresponding protruding finger element. The L-shaped notch and corresponding protruding finger element of the first block component is a reverse mirror image of the L-shaped notch and corresponding protruding finger element of the second block component such that the protruding finger elements of the first and second block components is received within the L-shaped recesses of the second and first block components, respectively.

According to some embodiments each of the opposed top and bottom faces of the side wall elements may include an elongate generally U-shaped recessed groove and an elongate generally U-shaped protruding tongue, respectively. Opposed end faces of the side wall elements include an elongate generally U-shaped recessed groove and an elongate generally U-shaped protruding tongue. The generally U-shaped grooves of the side wall elements co-terminate with respective adjacent ends of the generally U-shaped tongues at respective transverse edges of the side wall elements.

The interior wall element of each of the first and second block components according to certain other embodiments may be provided with at least one elongated alignment protrusion extending outwardly from a bottom face thereof. The first block component may therefore comprise a pair of the elongated alignment protrusions extending outwardly from the bottom face thereof. The alignment protrusions may be laterally separated from one another by substantially equal distances from one another.

The interior wall elements of each of the first and second block components can include an elongate recessed pocket to receive therein a respective one of the protrusions when correspondingly configured first and second blocks are stacked on top of one another in an alternating manner. The interior wall element of the first block component further may also include a generally rectangularly shaped recessed pocket oriented along a transverse elongate axis thereof which is adapted to receive therein a respective adjacent one of the alignment protrusions of a correspondingly configured first block component when stacked on top of one another in an alternating manner

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 of a partially completed exemplary coke oven wall structure in accordance with an embodiment of the present invention;

FIG. 2 is a top plan view of a partially completed course of the coke oven wall structure depicted in FIG. 1;

FIGS. 3-13 are views of a two-part wall block assembly employed in the coke oven wall structure depicted in FIG. 1, wherein FIG. 3 is a left top front perspective view thereof; FIG. 4 is a right top front perspective view of thereof; FIG. 5 is a right top rear perspective view thereof; FIG. 6 is left top rear perspective view thereof; FIG. 7 is a bottom perspective view thereof; FIG. 8 is a front elevation view thereof; FIG. 9 is a rear elevation view thereof; FIG. 10 is a top plan view thereof; FIG. 11 is a bottom plan view thereof; FIG. 12 is a right side elevation view thereof; and FIG. 13 is a left side elevation view thereof;

FIGS. 14-28 are views of a first block component of the two-part wall block assembly depicted in FIGS. 3-13, wherein FIG. 14 is a left top front perspective view thereof; FIG. 15 is a right top front perspective view of thereof; FIG. 16 is a right top rear perspective view thereof; FIG. 17 is a left top rear perspective view thereof; FIG. 18 is a bottom perspective view thereof; FIG. 19 is a top plan view thereof; FIG. 20 is a bottom plan view thereof; FIG. 21 is a front elevation view thereof; FIG. 22 is a rear elevation view thereof; FIG. 23 is a left side elevation view thereof; FIG. 24 is a right side elevation view thereof; FIGS. 25 and 26 are cross-sectional elevational views as taken along lines 25-25 and 26-26 in FIG. 19, respectively, and FIGS. 27 and 28 are enlarged detailed views of the encircled features shown in FIG. 21, respectively;

FIGS. 29-43 are views of a second block component of the two-part wall block assembly depicted in FIGS. 3-13 wherein FIG. 29 is a left top front perspective view thereof; FIG. 30 is a right top front perspective view of thereof; FIG. 31 is a right top rear perspective view thereof; FIG. 32 is a left top rear perspective view thereof; FIG. 33 is a bottom perspective view thereof; FIG. 34 is a top plan view thereof; FIG. 35 is a bottom plan view thereof; FIG. 36 is a front elevation view thereof; FIG. 37 is a rear elevation view thereof; FIG. 38 is a left side elevation view thereof; FIG. 39 is a right side elevation view thereof; FIGS. 40 and 41 are cross-sectional elevational views as taken along lines 40-40 and 41-41 in FIG. 34, respectively, and FIGS. 42 and 43 are enlarged detailed views of the encircled features shown in FIG. 34, respectively; and

FIGS. 44-48 are views of a quoin block component that may be employed at the terminal ends of the courses of the coke oven wall structures shown in FIGS. 1 and 2, wherein FIG. 44 is a front perspective view thereof; FIG. 45 is a top plan view thereof; FIG. 46 is a right side elevation view thereof, the left side elevation view being a mirror image thereof; and FIGS. 47 and 48 are a cross sectional elevational views thereof as taken along lines 47-47 and 48-48 in FIG. 45, respectively.

DETAILED DESCRIPTION

Accompanying FIG. 1 shows an exemplary coke oven wall structure 10 in accordance with an embodiment of the present invention 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 wall structures 10 defining therebetween regenerator regions provided with checker bricks associated with the individual coke ovens (not shown).

As shown in FIGS. 1 and 2, the wall structure 10 includes a number of substantially horizontally laid courses 10a each comprised of an end-to-end series of interconnected stacked blocks (a representative few of which are identified in FIG. 1 by reference numeral 12). Each of the individual blocks 12 are in turn constructed of a pair of interlocked opposing block components (a representative few of which are identified in FIG. 1 by reference numerals 20, 40). The stacked blocks 12 in the wall structure 10 define establish a number of substantially vertically oriented flue openings 14 therewithin so as to allow the passage therethrough of coke oven flue gases.

The orientation of the opposed interlocked block components 20, 40 in each course 10a is reversed as compared to the orientation of the block components 20, 40 in adjacent components. That is a block component 20 in one course 10a will be stacked between block components 40 in adjacent courses 10a, while conversely a block component 40 in one course 10a will be stacked between block components 20 in adjacent courses 10a. In the exemplary embodiment depicted, each course 10a of the wall structure 10 may terminate in a quoin block 60.

The blocks 12 and the opposed interlocked block components 20, 40 forming such blocks 12 are shown in greater detail in accompanying FIGS. 3-43. In this regard, each of the block components 20, 40 is generally an asymmetrical unitary T-shaped (hammerhead) block structure having an interior wall element 22, 42 which integrally (unitarily) formed at substantially a right angle (90°) to a side wall element 24, 44, respectively, so as to extend inwardly relative to the wall structure 10 when stacked in a course 10a. Since the interior wall element 22, 42 is asymmetrically joined to the side wall element 24, 44 so as to offset from the transverse centerline thereof, the side wall elements 24, 44 will include longer and shorter wall side wall segments 24a, 24b and 44a, 44b, respectively.

The terminal ends of each of the interior wall elements 22, 42 includes an L-shaped notch 22a, 42a that in turn establishes a protruding finger element 22b, 42b. As noted in the drawing FIGS. 3-43, the L-shaped notches 22a, 42a and the thus established protruding finger elements 22b, 42b of each block 20, 40 are offset relative to one another along a vertical bisecting plane to allow the later to be received within the former when the blocks 20, 40 are positioned in opposing relationship to one another. Thus, when positioned in opposing relationship to one another, the protruding finger elements 22b, 44b will be received within an opposed L-shaped recess 22a, 44a of each block 20, 40 so as to collectively define a cross-sectional thickness dimension of the interior wall elements 22, 44, respectively.

As noted previously, the blocks 20, 40 are adapted to being interconnected in an end-to-end manner in each of the courses 10a of the wall structure 10 and stacked on top of one another. In order to provide sealing against escape of flue gases from the flue channels 14, each of the top and bottom faces of the side wall elements 24, 44 will include an elongate generally U-shaped recessed groove 24-1, 44-1 and an elongate generally U-shaped protruding tongue 24-2, 44-2, respectively. Opposed end faces of the side wall elements 24, 44 will similarly include an elongate generally U-shaped recessed groove 24-3, 44-3 and an elongate generally U-shaped protruding tongue 24-4, 44-4, respectively. It will be noted that the grooves 24-1, 24-3 and 44-1, 44-3 of the side wall elements 24, 44 will co-terminate with respective adjacent ends of the generally U-shaped tongues 24-2, 44-2 and 24-4, 44-4 at respective transverse edges of the side wall elements 24, 44 in a manner similar to that described in US 2016/0145494 (the entire content of which is expressly incorporated hereinto by reference).

The bottom face of the interior wall element 22 will include a pair of elongated alignment protrusions 22-1, 22-2 extending outwardly therefrom while the bottom face of the interior wall element 42 will include a single elongated alignment protrusion 42-1. As can be seen in, e.g., FIG. 7, the alignment protrusions are laterally separated from one another by substantially equal distances so that the protrusions 22-1 and 42-1 are oriented on respective lateral sides of the central protrusion 22-2. The top faces of the interior wall elements 22, 42 will each include an elongate recessed pocket 22-3, 42-3 to receive therein a respective one of the protrusions 42-1, 22-1, respectively, when correspondingly configured blocks 22, 42 are stacked on top of one another in an alternating manner as described previously. The top face of the interior wall element 22 of block 20 will also include a generally rectangularly shaped recessed pocket 22-4 oriented along the elongate axis of thereof which is adapted to receive therein the central alignment protrusion 22-2 of a correspondingly configured block 22 when stacked on top of one another in an alternating manner.

A representative example of the quoin block 60 that may be employed in the wall structure 10 is shown in FIGS. 44-48. As can be seen the quoin block 60 has a widthwise (lateral) dimension that is adapted to be received between the opposed side wall segments 24a, 44a and 24b, 44b, respectively. If needed, spacer blocks 62 (see FIG. 1) may be provided to as to provide a flush end surface to the wall 10. A laterally elongate central boss 60a protrudes outwardly from the quoin block 60. Since a number of quoin blocks 60 are to be stacked on top of one another, a pair of laterally separated elongate protrusions 60-1 are provided on the bottom surface of the blocks 60 so as to be received within correspondingly configured laterally separated elongate recessed pockets 60-2 formed on a top surface of the blocks 60.

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 coke oven wall structure comprising a series of end-to-end interconnected blocks laid in alternating stacked courses defining opposed faces of the wall structure and internal flue openings, wherein each of the interconnected blocks comprise a pair of interconnected opposed first and second block components, whereinthe first and second block components each comprise a T-shaped unitary structure having an interior wall element which is integrally formed at substantially a right angle to a side wall element, the interior wall element extending inwardly relative to the opposed faces of the wall structure, whereinthe interior wall element is asymmetrically offset relative to a transverse centerline of the first and second block components so as to establish shorter and longer side wall elements thereof, and whereinthe interior wall element of each of the first and second block components includes a terminal end defining an L-shaped notch which establishes a corresponding protruding finger element, whereinthe L-shaped notch and corresponding protruding finger element of the first block component is a reverse mirror image of the L-shaped notch and corresponding protruding finger element of the second block component such that the protruding finger elements of the first and second block components is received within the L-shaped recesses of the second and first block components, respectively.

2. The coke oven wall structure according to claim 1, wherein each of the opposed top and bottom faces of the side wall elements include an elongate generally U-shaped recessed groove and an elongate generally U-shaped protruding tongue, respectively.

3. The coke oven wall structure according to claim 2, wherein opposed end faces of the side wall elements include an elongate generally U-shaped recessed groove and an elongate generally U-shaped protruding tongue.

4. The coke oven wall structure according to claim 3, wherein the generally U-shaped grooves of the side wall elements co-terminate with respective adjacent ends of the generally U-shaped tongues at respective transverse edges of the side wall elements.

5. The coke oven wall structure according to claim 1, wherein the interior wall element of each of the first and second block components includes at least one elongated alignment protrusion extending outwardly from a bottom face thereof.

6. The coke oven wall structure according to claim 5, wherein the first block component comprises a pair of the elongated alignment protrusions extending outwardly from the bottom face thereof.

7. The coke oven wall structure according to claim 6, the alignment protrusions are laterally separated from one another by substantially equal distances from one another.

8. The coke oven wall structure according to claim 5, wherein the interior wall elements of each of the first and second block components include an elongate recessed pocket to receive therein a respective one of the protrusions when correspondingly configured first and second blocks are stacked on top of one another in an alternating manner.

9. The coke oven wall structure according to claim 8, wherein the interior wall element of the first block component further includes a generally rectangularly shaped recessed pocket oriented along a transverse elongate axis thereof which is adapted to receive therein a respective adjacent one of the alignment protrusions of a correspondingly configured first block component when stacked on top of one another in an alternating manner

10. A block for a coke oven wall structure comprising a pair of interconnected opposed first and second block components, wherein each of the first and second block components comprise: a T-shaped unitary structure having an interior wall element which is integrally formed at substantially a right angle to a side wall element, the interior wall element extending inwardly relative to the opposed faces of the wall structure, whereinthe interior wall element is asymmetrically offset relative to a transverse centerline of the first and second block components so as to establish shorter and longer side wall elements thereof, and whereinthe interior wall element of each of the first and second block components includes a terminal end defining an L-shaped notch which establishes a corresponding protruding finger element, whereinthe L-shaped notch and corresponding protruding finger element of the first block component is a reverse mirror image of the L-shaped notch and corresponding protruding finger element of the second block component such that the protruding finger elements of the first and second block components is received within the L-shaped recesses of the second and first block components, respectively.

11. The block according to claim 10, wherein each of the opposed top and bottom faces of the side wall elements include an elongate generally U-shaped recessed groove and an elongate generally U-shaped protruding tongue, respectively.

12. The block according to claim 11, wherein opposed end faces of the side wall elements include an elongate generally U-shaped recessed groove and an elongate generally U-shaped protruding tongue.

13. The block according to claim 12, wherein the generally U-shaped grooves of the side wall elements co-terminate with respective adjacent ends of the generally U-shaped tongues at respective transverse edges of the side wall elements.

14. The block according to claim 10, wherein the interior wall element of each of the first and second block components includes at least one elongated alignment protrusion extending outwardly from a bottom face thereof.

15. The block according to claim 14, wherein the first block component comprises a pair of the elongated alignment protrusions extending outwardly from the bottom face thereof.

16. The block according to claim 15, the alignment protrusions are laterally separated from one another by substantially equal distances from one another.

17. The block according to claim 14, wherein the interior wall elements of each of the first and second block components include an elongate recessed pocket to receive therein a respective one of the protrusions when correspondingly configured first and second blocks are stacked on top of one another in an alternating manner.

18. The block according to claim 17, wherein the interior wall element of the first block component further includes a generally rectangularly shaped recessed pocket oriented along a transverse elongate axis thereof which is adapted to receive therein a respective adjacent one of the alignment protrusions of a correspondingly configured first block component when stacked on top of one another in an alternating manner

19. A course of a coke oven wall structure comprising a series of end-to-end interconnected blocks according to claim 10.

20. A coke oven comprising the coke oven wall structure according to claim 1.

21. A block component of a coke oven wall structure comprising: a T-shaped unitary structure having an interior wall element which is integrally formed at substantially a right angle to a side wall element, the interior wall element extending inwardly relative to opposed faces of the wall structure; whereinthe interior wall element includes a terminal end defining an L-shaped notch which establishes a corresponding protruding finger element, and whereinthe L-shaped notch and corresponding protruding finger element are configured to receive a portion of another block component of the wall structure.

22. The block component according to claim 21, wherein the interior wall element is asymmetrically offset relative to a transverse centerline of the block component so as to establish shorter and longer side wall elements thereof.

23. The block component according to claim 21, wherein the side wall element includes opposed top and bottom faces, and wherein at least one of the opposed top and bottom faces of the side wall element includes an elongate generally U-shaped recessed groove and/or an elongate generally U-shaped protruding tongue.

24. The block component according to claim 23, wherein the top face of the side wall element includes the elongate U-shaped groove.

25. The block component according to claim 23, wherein the bottom face of the side wall element includes the elongate U-shaped protruding tongue.