Refractory block and refractory wall assembly

Abstract

A refractory block for forming a wall structure comprising a body of cast refractory material. The body has a front face, a back face, a top face, a bottom face, and two opposing side faces. The body further has a projection formed on the top face and a recess formed in the bottom face, the projection being dimensioned to be received within the recess such that a projection on a block can be received in a recess on a block thereabove. A refractory anchor is embedded within the body. The anchor has a portion extending from the body through the back face.

1 . A refractory block for forming a wall structure, comprising: 
 a body of cast refractory material, said body having a front face, a back face, a top face, a bottom face, and two opposing side faces, said body further having a projection formed on said top face and a recess formed in said bottom face, said projection dimensioned to be received within said recess, such that a projection on a block can be received in a recess on a block thereabove; and    a refractory anchor embedded within said body, said anchor having a portion extending from said body through said back face.    
   
   
       2 . A refractory block as defined in  claim 1 , wherein said anchor extends through said block and has an end that projects through, and is coplanar with, said front face of said block.  
   
   
       3 . A refractory block as defined in  claim 1 , wherein said second end of said insert is flush with said front face of said block.  
   
   
       4 . A refractory block as defined in  claim 1 , wherein said block has a cube-like configuration.  
   
   
       5 . A refractory block as defined in  claim 1 , wherein said projection on said upper face is a rail-like shape that extends along said upper face of said block.  
   
   
       6 . A refractory block as defined in  claim 5 , wherein said recess has a channel-like shape that extends along the lower face of said block.  
   
   
       7 . A refractory block as defined in  claim 1 , wherein said extending portion of said anchor includes surface means for attaching said anchor to a shell of a furnace.  
   
   
       8 . A refractory block as defined in  claim 7 , wherein said surface means is an opening formed in said extending portion of said anchor.  
   
   
       9 . A refractory block as defined in  claim 8 , wherein said opening is a bore extending through said extending portion of said anchor.  
   
   
       10 . A refractory block as defined in  claim 9 , wherein said bore is cylindrical in shape and extends parallel to said back face.  
   
   
       11 . A refractory block as defined in  claim 1 , wherein each of said faces is flat and is perpendicular to contiguous faces.  
   
   
       12 . A refractory block as defined in  claim 1 , wherein said block is formed of about 45% to about 80% of coarse grained high alumina castable or a fused zirconia-mullite castable.  
   
   
       13 . A refractory block as defined in  claim 1 , further comprising a lifting device embedded in said block.  
   
   
       14 . A refractory block as defined in  claim 13 , wherein said lifting device is accessible through said top face.  
   
   
       15 . A refractory block as defined in  claim 14 , wherein said lifting device is an internal threaded sleeve embedded in said block, one end of said sleeve being accessible through said top face.  
   
   
       16 . A refractory block as defined in  claim 1 , wherein said anchor is wedge-shaped.  
   
   
       17 . A refractory block as defined in  claim 16 , wherein said anchor is an isopressed refractory.  
   
   
       18 . A furnace wall structure, comprised of: 
 a metallic wall panel;    a refractory wall parallel to and spaced apart from a metallic panel comprised of a plurality of stacked refractory blocks, each of said blocks comprised of:    a refractory body having a refractory anchor embedded therein, said anchor having a portion extending from said refractory block; said extending portion having an opening therein;    a plurality of bracket elements attached to said wall panel, said bracket elements disposed between said metallic wall panel and said refractory wall and each having a receiving opening; and    a fastener having a first portion dimensioned to be received in said receiving opening in said bracket and a second portion dimensioned to be received in said opening in said anchor, said fastener attaching said refractory blocks to said metallic panel.    
   
   
       19 . A furnace wall structure as defined in  claim 18 , wherein each of said refractory blocks forming said refractory wall is attached to said metallic wall panel by a fastener.  
   
   
       20 . A furnace wall structure as defined in  claim 18 , wherein said brackets are generally U-shaped and have spaced-apart leg portions, the ends of said leg portions being attached to said metallic wall panel.  
   
   
       21 . A furnace wall structure as defined in  claim 20 , wherein said brackets are pieces of metallic structural channels and are welded to said metallic wall panel.  
   
   
       22 . A furnace wall structure as defined in  claim 20 , wherein said receiving opening is defining between the legs of said U-shaped bracket.  
   
   
       23 . A furnace wall structure as defined in  claim 22 , wherein said receiving opening is vertically oriented.  
   
   
       24 . A furnace wall structure as defined in  claim 18 , wherein said refractory blocks forming said refractory wall are stacked in a staggered pattern.  
   
   
       25 . A furnace wall structure as defined in  claim 18 , further comprising a refractory material disposed within the space between said refractory wall and said metallic wall panel.  
   
   
       26 . A furnace wall structure as defined in  claim 18 , wherein said metallic wall panel is flat and is vertically oriented.  
   
   
       27 . A furnace wall structure as defined in  claim 18 , wherein said fastener is a generally U-shaped rod having spaced-apart leg portions, said leg portions being received in said receiving opening in said bracket and said opening in said fastener.  
   
   
       28 . A furnace wall structure as defined in  claim 18 , wherein each face of said refractory blocks is flat and is disposed at right angles to contiguous faces of said block.  
   
   
       29 . A furnace wall structure as defined in  claim 18 , wherein said refractory block includes a projection formed on a top face of said body and a recess formed on a bottom face of said body, said projection dimensioned to be received within said recess.  
   
   
       30 . A furnace wall structure as defined in  claim 29 , wherein said projection on said upper face is a rail-like shape that extends along said upper face of said block.  
   
   
       31 . A refractory block as defined in  claim 29 , wherein said recess has a channel-like shape that extends along the lower face of said block.