Patent Grant
12048955
This invention relates to refractory removal systems and methods. More particularly, to refractory removal systems and methods utilizing hydrodemolition.
Refractory has long been an indispensable component of manufacturing and processing industries involving high heat. The critical nature of refractory linings for processing metal, glass, chemical, mineral, energy and ceramics, and various other materials highlights the importance of such linings. Periodically, refractory linings may require maintenance or even removal. However, removal of refractory linings is a very time consuming and laborious task. For example, heavy equipment, such as jackhammers, may be utilized in prior techniques to remove the refractory lining, as well as the need for an operator inside the vessel operating such equipment which had and greatly increased injury risk and reduced safety.
Embodiments of improved refractory removal systems discussed herein may include one or more of the following assemblies/mechanisms: top or bottom assemblies; securing or extension mechanism(s) for controlling extension arms; nozzle assembly providing and controlling the nozzle; linear actuator mechanism for controlling movement of the nozzle/nozzle assembly along a central axis; and axial actuation mechanism or controlling movement away/toward the central axis.
In one embodiment, an improved refractory removal system may provide top, bottom, and nozzle assemblies. At least one of the top or bottom assemblies may provide a rotation mechanism that allows a nozzle of the nozzle assembly to be rotated about a central axis or axis of rotation. The system may provide one or more securing/extension mechanism(s) that allow the system to be secured in a desired position of a refractory vessel that refractory material is to be removed from. The system may provide an axial actuation mechanism that allows the nozzle to be moved away or towards the central axis. The system may also provide a linear actuation mechanism that allows the nozzle to be moved up or down along the central axis. It shall be recognized that the system provides at least three degrees of motion to the nozzle, thereby allowing the system to be utilized for a variety of situations.
In yet another embodiment, an improved refractory removal system may provide a combined top and bottom assembly or single assembly. The assembly may provide a rotation mechanism that allows a nozzle of the nozzle assembly to be rotated about a central axis or axis of rotation. The system may provide one or more securing/extension mechanism(s) that allow the system to be secured in a desired position of a refractory vessel that refractory material is to be removed from. The system may provide an axial actuation mechanism that allows the nozzle to be moved away or towards the central axis. The system may also provide a linear actuation mechanism that allows the nozzle to be moved up or down along the central axis. It shall be recognized that the system provides at least three degrees of motion to the nozzle, thereby allowing the system to be utilized for a variety of situations.
The foregoing has outlined rather broadly various features of the present disclosure in order that the detailed description that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter.
For a more complete understanding of the present disclosure, and the advantages thereof, reference is now made to the following descriptions to be taken in conjunction with the accompanying drawings describing specific embodiments of the disclosure, wherein:
Refer now to the drawings wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
Referring to the drawings in general, it will be understood that the illustrations are for the purpose of describing particular implementations of the disclosure and are not intended to be limiting thereto. While most of the terms used herein will be recognizable to those of ordinary skill in the art, it should be understood that when not explicitly defined, terms should be interpreted as adopting a meaning presently accepted by those of ordinary skill in the art.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention, as claimed. In this application, the use of the singular includes the plural, the word “a” or “an” means “at least one”, and the use of “or” means “and/or”, unless specifically stated otherwise. Furthermore, the use of the term “including”, as well as other forms, such as “includes” and “included”, is not limiting. Also, terms such as “element,” “assembly,” or “component” encompass both elements, assemblies, or components comprising one unit and elements, assemblies, or components that comprise more than one unit unless specifically stated otherwise.
Refractory or refractory material is a material that withstands or minimizes decomposition by heat, pressure, abrasion, erosion, corrosive, and/or chemical attack. Refractory is often utilized as a refractory lining in various vessels utilized for various types of manufacturing or processing. The refractory lining may be secured to the vessel with an anchoring system. These refractory linings may be exposed to harsh temperatures, pressures, abrasion, erosion, corrosion, and/or chemicals when utilized for various types of manufacturing or processing, which may result in the need for maintenance and/or removal despite the refractory material's resistance to such harsh conditions. Due to the properties of refractory materials, prior methods of removal is difficult and may require heavy equipment, chipping hammers, hydro-blast equipment as discussed previously. Further, prior methods may also require operator(s) inside refractory vessels during removal and present increased safety and injury risks.
Some methods have been explored regarding the possibility of hydro-demolition, commonly used in concrete removal, or the use of high-pressure and/or high flow water to remove refractory. However, these hydro-demolition systems have found it necessary to utilize high pressures and high flow to achieve acceptable removal of refractory. Further, such systems lack precision control of a water jet and cannot precisely control removal of refractory and positioning.
The systems 10 discussed herein utilize very low pressures and/or flow rates. In some embodiments, the pressure utilized for removal of refractory materials may be 1,500 PSI or less. In some embodiments, the pressure utilized for removal of refractory materials may be 3,000 PSI or less. In some embodiments, the pressure utilized for removal of refractory materials may be 5,000 PSI or less. In some embodiments, the pressure utilized for removal of refractory materials may be 7,500 PSI or less. In some embodiments, the pressure utilized for removal of refractory materials may be 10,000 PSI or less. In some embodiments, the flow rate utilized for removal of refractory materials may be 40 gallons/minute or less. In some embodiments, the flow rate utilized for removal of refractory materials may be 50 gallons/minute or less. In some embodiments, the flow rate utilized for removal of refractory materials may be 75 gallons/minute or less. In some embodiments, the flow rate utilized for removal of refractory materials may be 100 gallons/minute or less. In some embodiments, the system may be modular to allow easy assembly, disassembly, and transport.
The refractory removal system 10 may provide three general assemblies or a top assembly 20, nozzle assembly 30, and bottom assembly 40. The refractory removal system 10 may be powered hydraulically, electrically, or a combination thereof. An external module (not shown) may provide pump(s), controller(s), processor(s), electric power, and/or the like. Generally, the external module is responsible for supplying fluid and electric power to system 10, as well as controlling operation of the system as desired. The external module may be coupled to various components of the refractory removal system 10 by various hydraulic cables, electric cables, and/or the like, and may direct fluid and/or power to desired locations to control operation as desired. In other embodiments, it may be possible to incorporate components of the external module into the system 10, such as providing controllers locally near one or more mechanism(s) of the system.
Each of the assemblies of system 10 may include several parts facilitating desired functionality discussed further herein. Further, the size and scale of the refractory removal system 10 may be modified as desired for any desired application. As a nonlimiting example, sizing may vary to allow use in tubulars (e.g. 32″ or larger) or tanks (e.g. 4′ or larger)—however, the system 10 may be scaled down or up to accommodate vessels of different sizes and shapes. Yet another nonlimiting example, sizing may be varied to accommodate vessels ranging 32″ to 9′ in size or shape. The top 20 and bottom 40 assemblies may be separated by a set or adjustable distance with the nozzle assembly 30, which may include a track bar 50 and support bar(s) 60. The top 20 and bottom 40 assemblies allow placement or securing the system 10 in a desired position in a vessel. In some embodiments, the vessel may be tubular or cylindrical. However, the system 10 may accommodate vessels of other shapes with suitable programming. At least a portion of the top 20 and bottom 40 assemblies may remain stationary when secured in the vessel, while the nozzle assembly 30 may rotate if desired. The top 20 and bottom 40 assemblies may provide two or more extension arms 70, which may be adjusted inward or outward from a central axis or axis of rotation of the system 10 as desired to secure the system in the vessel. Once secured by extension arms 70, portions of the top 20 and bottom assemblies remain stationary relative to the vessel. One or more of the top 20 and bottom 40 assemblies may provide a rotary mechanism 80 that allow the nozzle assembly 30 to rotate about a central axis or axis of rotation (e.g. z-axis). Where one rotary mechanism 80 is provided by the top 20 or bottom 40 assemblies, the other assembly may provide a bearing mechanism that allows the nozzle assembly 30 to rotate. The nozzle assembly 30 allows adjustment of a nozzle 100 directing fluid for cutting the refractory materials.
It should be noted that directional discussion of the system 10 is from a perspective where the system is oriented vertically. However, it shall be understood by one of ordinary skill in the art that the system 10 is not in any way limited to vertical operation and may operate in any orientation desired. The system 10 allows at least three degrees of motion or freedom for the nozzle assembly 30 or nozzle 100, such as rotation about the central axis (or yaw); adjustment away from the central axis and adjustment toward the central axis (back & forth and/or left & right); and/or up and down along the central axis or height adjustment. In some embodiments, the system 10 allows for adjustability for the nozzle assembly 30 or nozzle 100 of 360° or greater rotation about the central axis or axis of rotation. It is preferable to prevent repeated rotation in embodiments where lines (e.g. hydraulic and/or electric) are connected to rotating components to avoid wrapping the lines around the system. However, some embodiments may facilitate connection to stationary component(s) that do not interfere with rotation. In some embodiments, the system 10 allows the nozzle 100 to be adjusted up and down along the central axis or allows height to be adjusted. In some embodiments, the system 10 allows the nozzle 100 to be adjusted toward or away from the central axis or side-to-side/back-and-forward. In some embodiments, adjustability for the nozzle up and down along the central axis may range from 0 to 5 feet. In some embodiments, adjustability for the nozzle away from and towards the central axis may range from 0 to 8 feet. In some embodiments, the system 10 may provide further degrees of motion, including pitch, and/or roll adjustment for nozzle 100. In some embodiments, incorporation of a camera may be desirable as well. It may also be desirable to provide a protective housing and/or clean system, as the harsh environment and debris may obstruct the view or damage the camera. The camera may be positioned in any suitable location such as near the nozzle. Further detailed discussion of each of the assemblies of the system 10 is provided herein.
The main body 105 may provide a linear actuation mechanism 90 that allows the main body to be moved up and down along the axis of rotation or central axis as desired (e.g.
While the embodiments shown provide top and bottom axial actuation mechanisms 200, other embodiment may involve different arrangements of axial actuation mechanism. As a nonlimiting example, another embodiment may incorporate an axial actuation mechanism 200 with the main body 105 of nozzle assembly 30 to allow the nozzle 100 to be axially adjusted. It should be noted this alternative embodiment would not require axial movement of the track bar 50 and main body 105, and could simply allow actuation of the nozzle 100.
While the embodiments shown illustrate simple extension arms 70, it may be desirable to provide more complex arms that allow the entire system 10 to move along a z-axis. As a nonlimiting example, motorized wheel(s) may be provided by the extension arms 70 that allow the entire system 10 to be moved along the z-axis. For example, in a lengthy vessel, such as a long tubular, such features may be desirable to avoid the need to repeatedly engage-disengage extension arms to traverse sections of the vessel. It should be noted that the z-axis referring to the central axis of the system 10 does not indicate orientation of a vessel. In other words, the system 10 may be utilized for removal of refractory from vertical or horizontal vessels. For example, the system 10 may be placed in a lengthy horizontal vessel, and after removal of refractory from a first section—the motorized wheels may move the system to a next section.
In addition to allowing a nozzle 100 to be moved up or down along the central axis or axis of rotation and away or towards the central axis, it is also desirable to allow the nozzle to be rotated about the central axis (e.g.
The rotation mechanism 80 may be implemented in a variety of ways and may comprise any suitable known components, such as gearing, guide(s), actuator(s), motor(s), belt(s), chain(s), sprocket(s), hydraulic actuator(s), and/or the like. As a nonlimiting example, the rotation mechanism 80 may comprise a gearing system 305 and actuators 315 that cause the nozzle 100 to rotate clockwise or counterclockwise as desired (e.g.
It shall be apparent to one of ordinary skill in the art that variations of the embodiments above are possible to accommodate a variety of different situations. Variations in refractory vessel shapes and/or sizes may make variations of the system or size of the system desirable to accommodate the different variations.
Shown in
Similar to the prior embodiment, an axial actuation mechanism 200 may be place near one end adjacent to the assembly 20, such as but not limited to a bottom end of assembly 20. The notable difference in the embodiment of
Whereas the embodiments above may desire a longer track bar, these embodiments may desire a shorter track bar 50 in some cases to minimize concerns about flexing, stability, or damage. Nonlimiting examples may provide a track bar 50 or a range of motion up/down along the track bar of about 4 feet. As the bottom end of track bar 50 does not require a rotating mechanism or bearing, a stopper or the like may be provided to stop a nozzle assembly (not shown) from disengaging from the system. While the nozzle assembly is not shown, it is similar to those discussed in embodiments above and may comprise any combination of components discussed previously above.
The following examples are included to demonstrate particular aspects of the present disclosure. It should be appreciated by those of ordinary skill in the art that the methods described in the examples that follow merely represent illustrative embodiments of the disclosure. Those of ordinary skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments described and still obtain a like or similar result without departing from the spirit and scope of the present disclosure.
The embodiments shown in
Embodiments described herein are included to demonstrate particular aspects of the present disclosure. It should be appreciated by those of skill in the art that the embodiments described herein merely represent exemplary embodiments of the disclosure. Those of ordinary skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments described, including various combinations of the different elements, assemblies, components, steps, features, or the like of the embodiments described, and still obtain a like or similar result without departing from the spirit and scope of the present disclosure. From the foregoing description, one of ordinary skill in the art can easily ascertain the essential characteristics of this disclosure, and without departing from the spirit and scope thereof, can make various changes and modifications to adapt the disclosure to various usages and conditions. The embodiments described hereinabove are meant to be illustrative only and should not be taken as limiting of the scope of the disclosure.
This application claims the benefit of U.S. Provisional Patent Application No. 62/978,065, filed on Feb. 18, 2020, which is incorporated herein by reference.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4253646 | Goto | Mar 1981 | A |
| 4328959 | Holtmann | May 1982 | A |
| 4570909 | Hiroki | Feb 1986 | A |
| 5601051 | Bajek | Feb 1997 | A |
| 7128074 | MacNeil | Oct 2006 | B2 |
| 8794712 | MacNeil | Aug 2014 | B2 |
| Number | Date | Country | |
|---|---|---|---|
| 20210252565 A1 | Aug 2021 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62978065 | Feb 2020 | US |
