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.

What is claimed is: 
     
         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, wherein   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, and wherein   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, and wherein   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, and wherein   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.   
     
     
         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.